Refrigerator Appliance and Corresponding Control System

This application claims the benefit of U.S. provisional application Ser. No. 63/640,312, filed Apr. 30, 2024, the disclosure of which is hereby incorporated in its entirety by reference herein.

The present disclosure relates to an appliance such as a refrigerator.

In order to keep food fresh, a low temperature must be maintained within a refrigerator to reduce the reproduction rate of harmful bacteria. Refrigerators circulate refrigerant and change the refrigerant from a liquid state to a gas state by an evaporation process in order cool the air within the refrigerator. During the evaporation process, heat is transferred to the refrigerant. After evaporating, a compressor increases the pressure, and in turn, the temperature of the refrigerant. The gas refrigerant is then condensed into a liquid and the excess heat is rejected to the ambient surroundings. The process then repeats.

A refrigerator includes a cabinet, a refrigeration system, an infrared camera, a controller, and a transmitter. The cabinet defines an internal cavity. The infrared camera is operable to monitor the internal cavity, monitor objects disposed within the internal cavity, and generate temperature data corresponding to temperatures within the internal cavity and temperatures of the objects. The refrigeration system is operable to cool the internal cavity and the objects. The controller is programmed to receive the temperature data from the infrared camera and in response to the temperature data including a temperature of at least one of the objects deviating from a range, control the refrigeration system to drive the temperature of the at least one of the objects toward the desired range. The transmitter is in communication with the controller and is operable to transmit the temperature data to an external device.

A refrigerator includes a refrigerant circuit, an infrared camera, and a controller. The refrigerant circuit has a compressor and is operable to cool an internal space defined within the refrigerator via activation of the compressor. The infrared camera is operable to create a temperature map of the internal space. The controller is programmed to receive the temperature map from the infrared camera and control the compressor based on the temperature map to drive a temperature of an object disposed within the internal space toward a desired range.

A refrigerator includes a refrigeration system, an infrared camera, and a controller. The refrigeration system is operable to cool an internal space defined within the refrigerator. The infrared camera is operable to create a temperature map of the internal space. The controller is programmed to receive the temperature map from the infrared camera, control the refrigeration system based the temperature map, and wirelessly transmit the temperature map to an external device.

Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments may take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the embodiments. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures may be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.

Referring to, generally a refrigeratorof the French-Door Bottom Mount type is illustrated. However, it should be understood that this disclosure could apply to any type of refrigerator, such as a side-by-side, two-door bottom mount, or a top-mount type. As shown in, the refrigeratormay have a first internal storage chamber or fresh food compartmentconfigured to refrigerate and not freeze consumables within the fresh food compartment, and a second internal storage chamber or a freezer compartmentconfigured to freeze consumables within the freezer compartmentduring normal use. The refrigeratorincludes panels or wallsthat form a housing or cabinet. The walls, housing, and/or cabinetdefine the fresh food compartmentand the freezer compartment. The wallsmay more specifically form an internal liner of the refrigerator. The wallsmay include a rear or back wall, a top wall, a bottom wall, and two side walls.

One or more shelvesmay be secured to the wallswithin the fresh food compartment. One or more drawersmay be slidably secured to the shelvesor the walls within the fresh food compartment. More specifically, the drawersmay be slidably secured to the shelvesor the walls within the fresh food compartmentvia tracks or rails. One or more of the drawersmay be either a pantry draweror a crisper drawer. Crisper drawermay more specifically be drawers defining a storage space that is kept at a desired humidity that may be different from the remainder of the fresh food compartment, but that is optimal for maintaining freshness of fruits and vegetables.

The refrigeratormay have one or more doors,that provide selective access to the interior volume of the refrigeratorwhere consumables may be stored. As shown, the fresh food compartment doors are designated, and the freezer door is designated. It may also be shown that the fresh food compartmentmay only have one door. The doorsmay be rotatably secured to the wallsby one or more hinges.

It is generally known that the freezer compartmentis typically kept at a temperature below the freezing point of water, and the fresh food compartmentis typically kept at a temperature above the freezing point of water and generally below a temperature of from about 35° F. to about 50° F., more typically below about 38° F.

The doorsmay each include an exterior paneland an interior panelthat is disposed on an internal side of the respective exterior panelof each door. The interior panelsmay be configured to face the fresh foodcompartment when the doorsare in closed positions (See). The interior panelmay more specifically be a door liner. An insulating material, such as an insulating foam, may be disposed between the exterior paneland interior panelof each doorin order reduce the heat transfer from the ambient surroundings and increase the efficiency of the refrigerator.

The doorsmay also include storage binsthat are able to hold food items or containers. The storage binsmay be secured to the interior panelsof each door. Alternatively, the storage binsmay integrally formed within or defined by the interior panelsof each door. In yet another alternative, a portion of the storage binsmay be secured to the interior panelsof each door, while another portion of the storage binsmay be integrally formed within or defined by the interior panelsof each door. The storage binsmay include shelves (e.g., a lower surface upon, which a food item or container may rest upon) that extend from back and/or side surfaces of the interior panelsof each door.

Referring to, the refrigeratorincludes refrigeration system. The refrigeration system includes a refrigeration loop or circuitthat is configured to cool the air the within the fresh food compartment, the freezer compartment, and/or other designated refrigerated space. The refrigeration loop or circuitmay also be referred to as a refrigerant loop or circuit. The refrigeration loop or circuitincludes at least a compressor, an evaporatorthat cools air being delivered to the fresh food compartment, the freezer compartment, and/or other refrigerated space, a condenserthat rejects heat to ambient surroundings, and an expansion device, such as a thermal expansion valve. The refrigeration loop or circuitmay also include an accumulator. The accumulatormay be located between the evaporatorand the compressor. The accumulatorprevents liquid refrigerant that did not evaporate in the evaporatorfrom flowing into the compressor. The refrigeration loop or circuitincludes lines or tubesthat are configured to transport the refrigerant between the evaporator, compressor, condenser, thermal expansion valve, and accumulator. The evaporatorand condenserare each heat exchangers (e.g., tube and fin heat exchangers).

Fansmay be utilized to direct air across the evaporatorand the condenserto facilitate exchanging heat. The air may be directed by the fansthrough flow paths, channels, or conduits. A first set of the conduitsmay direct the air across the evaporator, where the air is cooled during the flow cycles of the refrigerant through the refrigeration loop or circuit. The cooled air is then directed into the fresh food compartment, the freezer compartment, and/or other refrigerated space. A second set of the conduitsmay direct the air across the condenser, where the air is heated during the flow cycles of the refrigerant through the refrigeration loop or circuit. The heated air is then directed to the ambient surroundingsto reject the heat regenerated during the flow cycles of the refrigerant through the refrigeration loop or circuit.

One or more dampersmay be disposed within at least one of the conduitsto either increase or decrease air flow across the evaporator. Opening the damper, which may be disposed between the evaporatorand a refrigerated compartment (e.g., the fresh food compartment, the freezer compartment, or other refrigerated space) increases cooling within such a refrigerated compartment, while closing the damper decreases cooling within the refrigerated compartment. The compressor, the fans, and the dampersmay be connected to a controller.

Sensorsthat measure the air temperature and/or humidity within the fresh food compartment, the freezer compartment, and/or other refrigerated space may be in communication with the controller, and may be configured to generate and deliver temperature and/or humidity data (e.g., the air temperature and/or humidity within the fresh food compartment, the freezer compartment, and/or other refrigerated space) to the controller. Alternatively, or in addition to the sensors, one or more infrared camerasmay be disposed within the fresh food compartment, the freezer compartment, and/or other refrigerated space, where the one or more infrared camerasare configured to measure the temperature of objects (e.g., food items) disposed within the fresh food compartment, the freezer compartment, and/or other refrigerated space.

The one or more infrared camerasare configured to generate and deliver temperature data (e.g., the air temperature and/or humidity within the fresh food compartment, the freezer compartment, and/or other refrigerated space or the temperature of one or more items disposed within the fresh food compartment, the freezer compartment, and/or other refrigerated space) to the controller.

The controllermay be configured to activate and/or operate the refrigeration system (or more specifically the controllermay be configured to activate and/or operate specific components of the refrigeration system such as the compressor, fans, open dampers, etc.) in response to the air temperature and/or humidity (e.g., determined via the sensors) within the fresh food compartment, the freezer compartment, and/or other refrigerated space being greater than or exceeding a first temperature threshold or setpoint, or in response to a temperature of one or more objects (e.g., determined via the one or more infrared cameras) disposed within the fresh food compartment, the freezer compartment, and/or other refrigerated space being greater than or exceeding the first temperature threshold or setpoint.

The controllermay also be configured to deactivate or shut down the refrigeration system (or more specifically the controllermay be configured to deactivate or shut down specific components of the refrigeration system such as compressor, fans, close dampers, etc.) in response to the air temperature and/or humidity (e.g., determined via the sensors) within the fresh food compartment, the freezer compartment, and/or other refrigerated space being less than or falling below a second temperature threshold or setpoint, or in response to a temperature of one or more objects (e.g., determined via the one or more infrared cameras) disposed within the fresh food compartment, the freezer compartment, and/or other refrigerated space being less than or falling below the second temperature threshold or setpoint.

The system may include a hysteresis such that the acceptable temperature of the fresh food compartment, the freezer compartment, and/or other refrigerated space (or the temperature of one or more items disposed within the fresh food compartment, the freezer compartment, and/or other refrigerated space) corresponds to a desired range between the first and second temperature thresholds. For example, the first temperature threshold may be greater than the second temperature threshold such that the controllerinitiates cooling via operating the compressor, fans, dampers, etc. once the temperature of fresh food compartment, the freezer compartment, and/or other refrigerated space (or the temperature of one or more items disposed within the fresh food compartment, the freezer compartment, and/or other refrigerated space) reaches or exceeds first temperature threshold but does not cease operating the operating the compressor, fans, dampers, etc. until the temperature of fresh food compartment, the freezer compartment, and/or other refrigerated space (or the temperature of one or more items disposed within the fresh food compartment, the freezer compartment, and/or other refrigerated space) drops to or below the second threshold. The compressor, fans, dampers, etc. may then remain shut down until the temperature of fresh food compartment, the freezer compartment, and/or other refrigerated space (or the temperature of one or more items disposed within the fresh food compartment, the freezer compartment, and/or other refrigerated space) once again reaches or exceeds the first threshold.

The controllermay be part of a larger control system and may be controlled by various other controllers throughout the refrigerator, and one or more other controllers can collectively be referred to as a “controller” that controls various functions of the refrigeratorin response to inputs or signals to control functions of the refrigerator. The controllermay include a microprocessor or central processing unit (CPU) in communication with various types of computer readable storage devices or media (e.g., a non-transitory computer readable medium having instructions stored thereon). Computer readable storage devices or media may include volatile and nonvolatile storage in read-only memory (ROM), random-access memory (RAM), and keep-alive memory (KAM), for example. KAM is a persistent or non-volatile memory that may be used to store various operating variables while the CPU is powered down. Computer-readable storage devices or media may be implemented using any of a number of known memory devices such as PROMs (programmable read-only memory), EPROMS (electrically PROM), EEPROMs (electrically erasable PROM), flash memory, or any other electric, magnetic, optical, or combination memory devices capable of storing data, some of which represent executable instructions, used by the controllerin controlling the refrigerator.

Control logic or functions performed by the controllermay be represented by flow charts or similar diagrams in one or more figures. These figures provide representative control strategies and/or logic that may be implemented using one or more processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. As such, various steps or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Although not always explicitly illustrated, one of ordinary skill in the art will recognize that one or more of the illustrated steps or functions may be repeatedly performed depending upon the particular processing strategy being used. Similarly, the order of processing is not necessarily required to achieve the features and advantages described herein, but is provided for case of illustration and description. The control logic may be implemented primarily in software executed by a microprocessor-based controller, such as controller. Of course, the control logic may be implemented in software, hardware, or a combination of software and hardware in one or more controllers depending upon the particular application. When implemented in software, the control logic may be provided in one or more computer-readable storage devices or media having stored data representing code or instructions executed by a computer to control the refrigeratoror its subsystems. The computer-readable storage devices or media may include one or more of a number of known physical devices which utilize electric, magnetic, and/or optical storage to keep executable instructions and associated calibration information, operating variables, and the like.

Current solutions for controlling the temperature within a refrigerated space (e.g., a refrigerator cavity such as the fresh food compartmentor the freezer compartment) rely on monitoring air temperature of the compartment or supply air channel. This may not provide an estimate of the temperature of specific food items disposed within such a refrigerated space. Different food items in the refrigerator may have different densities and characteristics. Therefore, the rate of cooling of such different food items may also differ. Monitoring air temperature within a refrigerated space may not include monitoring heat losses. Such a system will continue to cool the refrigerated space until the air within refrigerated space cools down to a set point or threshold, which could lead to inefficiencies.

The proposed solution described herein, may monitor the temperature of objects within the refrigerated space (e.g., the fresh food compartment, the freezer compartment, and/or other refrigerated space) via the one or more infrared cameras. Furthermore, the one or more infrared camerasmay generate a temperate or heat map of the items within the refrigerated space, which may illustrate the temperatures the specific items disposed within the refrigerated space. The one or more infrared camerasmay communicate to the controllerif the specific items disposed within the refrigerated space are over-cooling or freezing. The controllermay then control the compressor, the fans, the dampers, etc. to adjust the amount of cooling being delivered to the refrigerated space to prevent the specific items disposed within the refrigerated space from over-cooling or freezing, which operates to prevent wastage of food and waste of energy spent in cooling the refrigerated space. The controllermay send a notification to a user interfaceof the refrigerator that includes a display to notify a user that items in the refrigerated space are over-cooling or freezing. The controllermay also or alternatively send a notification to an external device or mobile device(e.g., a smartphone, laptop, personal assistant device, tablet, etc.) via wireless communication (e.g., a mobile network, Bluetooth®, Wi-Fi, etc.) to notify a user that items in the refrigerated space are over-cooling or freezing. The controllerand external or wireless devicemay each include or may each be connected to transmitters, receivers, transceivers, antennas, etc. to facilitate wireless communication.

The one or more infrared camerasmay be used in a special compartment or drawer (e.g., one of the drawers, such as pantry draweror crisper drawer) with the refrigeratorwhere the temperature of an object or item disposed within the special compartment may be monitored, and cooling may be accomplished relatively quickly. Based on the set point or desired temperature of the item or object, the system will continue to operate the compressor, until the desired temperature is of the object or item is obtained as observed by the one or more infrared cameras. Since air temperature and actual temperature of the item may be different, current systems that utilize air temperature within a refrigerated space to control cooling in the refrigerated space may guess as to whether or not items placed within the refrigerated space are actually cooled down to desired temperature. Using infrared cameras, on the other hand, allows items or objects disposed within a refrigerated space to be actively cooled until these items or objects reach desired temperatures. This may be particularly advantageous for items that require to be stored at specific temperatures (e.g., medicines).

The one or more infrared camerasmay also be utilized to map the temperature within the refrigerated space (e.g., the fresh food compartment, the freezer compartment, and/or other refrigerated space) against or relative to the desired set point or desired temperature. This will prevent cooling losses that can occur due to poor seals. This data may also be used for providing pro-active service to the customers. Such a temperature or heat map could be displayed at the user interfaceor on a mobile device.

It should be understood that the refrigeration loop or circuitand corresponding system/components illustrated inare for illustrative purposes only and that the system inmay be reconfigured. For example, the refrigeratormay include two refrigeration loops or circuits, where one of the refrigeration loops or circuitsis configured to cool air entering the fresh food compartmentwhile the second of the refrigeration loops or circuitsis configured to cool air entering the freezer compartment. As another example, the refrigeration loop or circuitmay include two evaporators, wherein one is configured to cool air entering the fresh food compartmentwhile the other is configured to cool air entering the freezer compartment.

Referring to, a methodfor controlling the cooling the system (e.g., the refrigeration loop or circuitand the corresponding system/components illustrated in) for a refrigerated space or compartment (e.g., a refrigerator cavity such as the fresh food compartment, the freezer compartment, special compartment, or drawer (e.g., one of the drawers, such as pantry draweror crisper drawer) of a refrigerator appliance) is illustrated. The methodbeings at blockwhere the temperature of one or more items disposed within the refrigerated space is monitored (e.g., via the one or more infrared cameras). Next, the methodmoves on to blockwhere the cooling system of the refrigerated space is controlled to drive the temperature of the one or more items disposed within the refrigerated space toward desired set points or desired temperatures. More specifically, at block, the controllermay control the compressor, the fans, the dampers, etc. to adjust the cooling being delivered to the refrigerated space to drive the items disposed within the refrigerated space toward desired temperatures and to prevent the items disposed within the refrigerated space from over-cooling or freezing.

Moving on to block, if the temperatures of the items within the refrigerated space are outside of a threshold from the desired set points (e.g., if the items have temperatures that are lower than the desired set points by at least a threshold, if the items are freezing, or if the items have temperatures that are higher than the desired set points by at least a threshold after a predetermined time period in spite of cooling the refrigerated space), the methodmay notify the user that the temperatures of the items are not reaching the desired set point temperatures. Next, the method moves on to blockwhere the cooling system (or more specifically the one or more infrared camerasand the controller) is utilized to generate a temperature or heat map of the refrigerated space, including the items within the refrigerated space. The temperature or heat map is then communicated to the user (e.g., via the user interfaceor wirelessly to the mobile device) at block. The temperature or heat map may be indicative of whether or not items are being sufficiently cooled within the refrigerated space or if the refrigerated space is being sufficiently sealed. In the event there is insufficient cooling or sealing of the refrigerated space, the communication of the temperature or heat map may include a special notification, alert, or warning of the insufficiency or insufficiencies. Furthermore, communication may occur at blockto a repair or service center where appropriate maintenance may be scheduled or required replacement parts (e.g., new seals around the refrigerator door) may be ordered.

The steps at blocks,, andmay be separated from blocksandsuch that the blocks,, andform a first method and blocksandform a second method. Furthermore, it should be understood that the flowchart inis for illustrative purposes only and that the methodshould not be construed as limited to the flowchart in. Some of the steps of the methodmay be rearranged while others may be omitted entirely.

The solution described herein prevents over cooling or freezing of produce. Controlling the temperature of the air in the refrigerated space may not equally cool all the items. Some items may cool sooner than others or some items could semi-freeze. The one or more infrared camerasmonitor the temperature of the items in the refrigerated space and, in conjunction with the controller, facilitate adjusting the amount of cooling to the refrigerated space and/or notifying the consumer or user in response to the temperature of the items within the refrigerated space decreasing to lower than optimum temperatures.

The solution described herein also facilitates reliable and fast cooling within a special compartment or drawer (e.g., one of the drawers, such as pantry draweror crisper drawer). The consumer or user may set a target temperature for cooling an item within such a special compartment or cooling drawer to cool the item as soon as possible or within a desired timeframe that may be shorter than a standard timeframe. The infrared cameramay constantly monitor the temperature of the target item while the system may use the temperature reading of the item (as opposed to the air temperature) and maintain operation of the compressoruntil the item has reached the setpoint or desired temperature. The consumer or user may be notified via the user interfaceor on a mobile devicewhen the item has reached the desired temperature.

The solution described herein may be utilized to maintain temperatures of critical items or temperature sensitive items such as medicine.

The solution described herein also may be utilized to check for temperature losses in the refrigerator cabinetin the form of a temperature or heat map. Such a temperature or heat map may be a temperature or heat map of the inside of the refrigerator cabinetwithin a refrigerated space (e.g., the fresh food compartment, the freezer compartment, and/or other refrigerated space (e.g., one of the drawers, such as pantry draweror crisper drawer)). This will facilitate identifying leaks occurring due to poor seals or poor alignment of the refrigerator door. The refrigerator controllermay automatically contact a repair or service center via transmitters, receivers, transceivers, antennas, etc. when a leakage issue is detected, order replacement parts, and/or schedule appropriate service.

It should be understood that the designations of first, second, third, fourth, etc. for any component, state, or condition described herein may be rearranged in the claims so that they are in chronological order with respect to the claims. Furthermore, it should be understood that any component, state, or condition described herein that does not have a numerical designation may be given a designation of first, second, third, fourth, etc. in the claims if one or more of the specific component, state, or condition are claimed.

The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments may be combined to form further embodiments that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics may be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. As such, embodiments described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.