US20170314833A1 - Refrigerator with thermoelectric device control process for an icemaker - Google Patents

Abstract

A refrigerator that has a fresh food compartment, a freezer compartment, and a door that provides access to the fresh food compartment is disclosed. An icemaker is mounted remotely from the freezer compartment. The icemaker includes an ice mold with an icemaking cycle having a liquid to ice phase change. A thermoelectric device has a cold side and a warm side. A controller is in operable communication with an input to the thermoelectric device. A sensor is in operable communication with the input to the thermoelectric device and the controller. A feedback response from the input to the thermoelectric device monitors the liquid to ice phase change of the icemaking cycle.

Description

CROSS-REFERENCE TO RELATED APPLICATION
• This application claims priority to U.S. Non-Provisional application Ser. No. 15/414,023 filed Jan. 24, 2017, which claims priority to Non-Provisional application Ser. No. 13/691,916, filed on Dec. 3, 2012, both entitled REFRIGERATOR WITH THERMOELECTRIC DEVICE CONTROL PROCESS FOR AN ICEMAKER, the disclosures of which are hereby incorporated herein by reference in their entireties.
FIELD OF THE DEVICE
• The invention relates generally to refrigerators with icemakers, and more particularly to refrigerators with the icemaker located remotely from the freezer compartment.
BACKGROUND OF THE INVENTION
• Household refrigerators commonly include an icemaker to automatically make ice. The icemaker includes an ice mold for forming ice cubes from a supply of water. Heat is removed from the liquid water within the mold to form ice cubes. After the cubes are formed they are harvested from the ice mold. The harvested cubes are typically retained within a bin or other storage container. The storage bin may be operatively associated with an ice dispenser that allows a user to dispense ice from the refrigerator through a fresh food compartment door.
• To remove heat from the water, it is common to cool the ice mold. Accordingly, the ice mold acts as a conduit for removing heat from the water in the ice mold. When the icemaker is located in the freezer compartment this is relatively simple, as the air surrounding the ice mold is sufficiently cold to remove heat and make ice. However, when the icemaker is located remotely from the freezer compartment, the control and removal of heat from the ice mold is more difficult.
• Therefore, the proceeding disclosure provides improvements over existing designs.
SUMMARY OF THE INVENTION
• According to one aspect, a refrigerator that has a fresh food compartment, a freezer compartment, and a door that provides access to the fresh food compartment is disclosed. An icemaker mounted remotely from the freezer compartment. The icemaker includes an ice mold with an icemaking cycle having a liquid to ice phase change. A thermoelectric device has a cold side and a warm side. A controller is in operable communication with an input to the thermoelectric device. A sensor is in operable communication with the input to the thermoelectric device and the controller. And, a feedback response from the input to the thermoelectric device monitors the liquid to ice phase change of the icemaking cycle. An ice to liquid phase change may also be monitored for an ice harvesting cycle or fresh ice production cycle.
• According to another aspect, an icemaker is disclosed. The icemaker includes an ice mold with an icemaking cycle having a liquid to ice phase change and a thermoelectric device that has a cold side and a warm side. An input is provided to the thermoelectric device. A controller is in operable communication with the thermoelectric device and the input. A sensor is in operable communication with the thermoelectric device. A feedback response from the thermoelectric device to the controller is provided for monitoring the liquid to ice phase change of the icemaking cycle. An ice to liquid phase change may also be monitored for an ice harvesting cycle or fresh ice production cycle.
• According to another aspect, a method for cooling in a refrigerator that has a fresh food compartment, a freezer compartment, and a door that provides access to the fresh food compartment is disclosed. The method provides an icemaker mounted remotely from the freezer compartment; the icemaker including an ice mold with an icemaking cycle having a liquid to ice phase. A thermoelectric device is also provided that has a cold side and a warm side. An input to the thermoelectric device is controlled using a controller in operable communication with the input and the thermoelectric device. A signal is sensed from a sensor in operable communication with the input to the thermoelectric device and the controller. The feedback response from the input to the thermoelectric device is monitored for determining the liquid to ice phase change of the icemaking cycle or an ice to liquid phase change for an ice harvesting cycle or fresh ice production cycle.
BRIEF DESCRIPTION OF THE DRAWINGS
• While the specification concludes with claims particularly pointing out and distinctly claiming the invention, it is believed that the various exemplary aspects of the invention will be better understood from the following description taken in conjunction with the accompanying drawings, in which:
• FIG. 1 is a perspective view illustrating exemplary aspects of a refrigerator;
• FIG. 2 is a perspective view showing an exemplary embodiment of an icemaker;
• FIG. 3 is a schematic illustration of a thermoelectric device according to one exemplary embodiment;
• FIG. 4 is a flow diagram illustrating a process for intelligently controlling one or more operations of the exemplary configurations and embodiments of the disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
• Referring to the figures, there is generally disclosed inFIGS. 1-4 arefrigerator10 configured to dispense ice from anicemaker102 chilled by athermoelectric device50 cooled by fluid or air taken from the fresh food compartment orrefrigerator compartment14 or thefreezer compartment16. Therefrigerator10 includes acabinet body12 with a refrigerator compartment orfresh food compartment14 selectively closeable by arefrigerator compartment door18 and afreezer compartment16 selectably closeable by afreezer compartment door20. Adispenser22 is included on arefrigerator compartment door18 for providing dispensions of liquid and/or ice at therefrigerator compartment door18. Although one particular design of arefrigerator10 is shown inFIG. 1, other styles and configurations for a refrigerator are contemplated. For example, therefrigerator10 could be a side-by-side refrigerator, a traditional style refrigerator with the freezer compartment positioned above the refrigerator compartment (top-mount refrigerator), a refrigerator that includes only a refrigerator or fresh food compartment and no freezer compartment, etc. In the figures is shown a bottom-mount refrigerator10 where thefreezer compartment16 is located below therefrigerator compartment14.
• Arefrigerator10, such as illustrated inFIG. 1 may include afreezer compartment16 for storing frozen foods, typically at temperatures near or below 0 .degree. Fahrenheit, and a fresh food section or refrigeratedcompartment14 for storing fresh foods at temperatures generally between 38 .degree. Fahrenheit and about 42 .degree. Fahrenheit. It is common to include icemakers and ice dispensers in household refrigerators. In a side-by-side refrigerator, where the freezer compartment and the fresh food compartment are located side-by-side and divided by a vertical wall or mullion, the icemaker and ice storage bin are generally provided in the freezer compartment and the ice is dispensed through the freezer door. In recent years it has become popular to provide so-called bottom mount refrigerators wherein the freezer compartment is located below the fresh food compartment, at the bottom of the refrigerator. It is advantageous to provide ice dispensing through the refrigeratedcompartment door18 so that thedispenser22 is at a convenient height. In bottom mount refrigerators the icemaker and ice storage may be provided within a separate insulated compartment108 located generally within or adjacent to, but insulated from, the fresh food compartment.
• To remove heat from the water, it is common to cool theice mold106 specifically. Accordingly, theice mold106 acts as a conduit for removing heat from the water in the ice mold. As an alternative to bringing freezer air to the icemaker, aheat exchanger50 comprising a thermoelectric device (TEC)50 may be used to chill theice mold106. The thermoelectric device is a device that uses the Peltier effect to create a heat flux when an electric current is supplied at the junction of two different types of materials. The electrical current creates a component with a warm side and cold side. Thermoelectric devices are commercially available in a variety of shapes, sizes, and capacities. Thermoelectric devices are compact, relatively inexpensive, can be carefully calibrated, and can be reversed in polarity to act as heaters to melt the ice at the mold interface to facilitate ice harvesting. Generally, thermoelectric devices can be categorized by the temperature difference (or delta) between its warm side and cold side. In the ice making context this means that the warm side must be kept at a low enough temperature to permit the cold side to remove enough heat from theice mold106 to make ice at a desired rate. Therefore, the heat from the warm side of the thermoelectric device must be removed to maintain the cold side of the mold sufficiently cold to make ice. Removing enough heat to maintain the warm side of the thermoelectric device at a sufficiently cold temperature creates a challenge.
• An additional challenge for refrigerators where theicemaker102 is located remotely from the freezer compartment is the ability to control temperature of theice mold106 for facilitating, for example, ice production and harvesting while using the least amount of energy.
• Several aspects of the disclosure addressing the aforementioned challenges are illustrated in the views ofrefrigerator10 and flow diagram provided in the figures.
• In connection with thedispenser22 in thecabinet body12 of therefrigerator10, such as for example on therefrigerator compartment door18, is anicemaker102 having anice mold106 for extracting heat from liquid within the ice mold to create ice which is dispensed from theice mold106 into an ice storage bin104. The ice is stored in the ice storage bin104 until dispensed from thedispenser22. Theice mold106 oricemaker102 may include aheat sink56 for extracting heat from theice mold106 using fluid or air as the heat extraction medium. Fluid or air for chilling theice mold106 may be transferred from thefreezer compartment16 directly to theicemaker102 or through therefrigerator compartment14 to theicemaker102 on therefrigerator compartment door18. For example, aheat sink56 may be positioned in thermal contact with theice mold106 to remove heat from theice mold106.
• Athermoelectric device50 may also be positioned at theicemaker102 with itscold side54 in thermal contact with theice mold106 and its warm side in thermal contact with theheat sink56. For example, in operation, if theheat sink56 can be kept generally at or near 20 .degree. Fahrenheit thewarm side52 of thethermoelectric device50 may be kept at or near 20 .degree. Fahrenheit. Thecold side54 of thethermoelectric device50 may be then kept at 20 .degree. Fahrenheit minus the delta of thethermoelectric device50. For example, if the thermoelectric device has a delta of 20 .degrees, thecold side54 may be kept at a temperature of 0 .degree. Fahrenheit. Theice mold106 may then be kept at or near the temperature of thecold side54 of thethermoelectric device50.
• FIG. 3 illustrates an exemplary embodiment of an icemaker configured so that theice mold106 may be chilled or heated using athermoelectric device50 using, for example, the process shown inFIG. 4. As previously indicated, thethermoelectric device50 includes acold side54 and an oppositewarm side52. Thecold side54 is in thermal contact withice mold106. And, thewarm side52 is in thermal contact with theheat sink56. Using the Peltier effect, a temperature difference is created between thecold side54 andwarm side52 of thethermoelectric device50. According to one aspect of the invention, asubstrate74 having a high thermal conductivity may be configured between theice mold106 andconductor60 at thecold side54 of thethermoelectric device50. On the opposite side of thethermoelectric device50, asubstrate58 having a high thermal conductivity may be configured in thermal contact with theheat sink56 andconductor68. Configured betweenconductors60 andconductors68 are negative-type pellets62 and positive-type pellets64 for providing a flow pathway forcharge carriers66. Apower source70 is connected toconductors68 for providing a current72 to thethermoelectric device50. The voltage and amperage of thepower source70 may be controlled according to one aspect of the disclosure. Using one or more sensors and/or monitoring one or more inputs to thethermoelectric device50, a system (seeFIG. 4) may be configured to monitor a liquid to ice phase change for fluid contained in theice mold106. Alternatively, the system may be configured to monitor an ice to liquid phase change, such as for example, in an ice harvesting cycle or a fresh ice production cycle. By reversing the polarity of thethermoelectric device50, thewarm side52 andcold side54 are swapped so that the ice mold would be in thermal contact with a warm side of thedevice50 and theheat sink56 would be in thermal contact with the cold side of thedevice50. Although thethermoelectric device50 is described as being in thermal contact with theice mold106, the disclosure contemplates that a fluid or air pathway could be configured in thermal contact with theice mold106 and thethermoelectric device50 to chill or warm theice mold106 from a remotely positionedthermoelectric device50.
• Temperature control for thethermoelectric device50 may be configured to use a thermostatic temperature control or a steady-state temperature control. With a thermostatic control, a thermal load is maintained between two temperature limits. For example, in an ice making cycle, the intelligent control (as shown inFIG. 4)200 may be figured to energize thepower source210 when a thermal load rises to or above 32 .degree. Fahrenheit then turning off thepower source210 when the temperature cools to 29 .degree. Fahrenheit. The system would then therefore be continually varying the temperature between 29 .degree. and 32 .degree. Fahrenheit. To monitor operating temperatures of thethermoelectric device50 during a liquid to ice phase change or a ice toliquid phase change208, one ormore sensors202 may be configured at locations to sense thetemperature228 of, for example, theice mold224, theheat sink222 or a substrate226 (e.g., a conductor). Thesubstrates226 in thermal contact with theice mold224 or theheat sink222 may also be configured withsensors202 to monitor thetemperature228 to determine the liquid to ice phase change or the ice toliquid phase change208. Alternatively,conductors60 or68 may be configured with one ormore sensors202 for monitoring thetemperature228 of a liquid to ice phase or ice toliquid phase change208. Theintelligent control200 can be configured to control the flowrate of air or liquid to theheat sink222 depending upon thetemperature228 sensed by one ormore sensors202 at theheat sink222. Thus, according to one aspect of the disclosure, one ormore sensors202 may be configured at theicemaker220 to monitor thetemperature228 of aheat sink222 in thermal contact with theice mold224 or asubstrate226 in thermal contact with theice mold224 or theheat sink222. Using theintelligent control200 to monitor thetemperature228 using one ormore sensors202 at the above described locations provides one way of monitoring the liquid to ice or ice toliquid phase change208 being driven by thethermoelectric device206. The rate of flow of liquid or air to theheat sink222 may be controlled by theintelligent control200 to control thetemperature228 of the warm side of thethermoelectric device206. If, for example, theintelligent control200 determines from a reading from thesensor202 that the phase of the liquid orice208 is not at atemperature228 to change, whether to ice or whether to liquid depending on whether an ice production, ice harvesting or fresh ice production cycle is being performed, theintelligent control200 may provide a correction to increase or decrease thetemperature228 by increasing/decreasing the flowrate of air or liquid to theheat sink56.
• In addition to controlling the rate of flow across theheat sink222 of theicemaker220, theinputs204 for operating thethermoelectric device206 may be controlled usingintelligent control200 to control the liquid to ice or ice toliquid phase change208 in theice mold224 of theicemaker220. For example, thethermoelectric device206 may be operated in a steady-state control by varying the inputs to thethermoelectric device206 using anintelligent control200. In one aspect, theintelligent control200 varies thepower inputs210 to thethermoelectric device206 to maintain theice mold224 of theicemaker220 at a desiredtemperature228. In operation, for example, the intelligent control monitors thetemperature228 via one ormore sensors202 at theice mold224 of the icemaker220 (assuming that thetemperature228 of theice mold224 is generally indicative of the liquid to ice or ice toliquid phase208 of the liquid in theice mold224 of the icemaker220). Theintelligent control200 may also be configured to alter thetemperature228 of thethermoelectric device206 by changing one or more of theinputs204, such as thepower210. In one aspect of the invention, thevoltage212 of thepower source210 may be controlled by theintelligent control200 to maintain thetemperature228 across thethermoelectric device206 at a desiredtemperature228 for the liquid to ice phase or ice toliquid phase change208 to occur in theice mold224. Similarly, theamperage214 of thepower source210 supplied as aninput204 to thethermoelectric device206 may be controlled using theintelligent control200 for controlling thetemperature228 of the liquid to ice or ice toliquid phase change208 in theice mold224. Thepower210 supplied as aninput204 to thethermoelectric device206 may also be varied using pulse-width modulation (PSM)216 or a variable direct current218 such as linear control. Usingpulse width modulation216 to controlpower210 as aninput204 to thethermoelectric device206, the frequency for pulsing thethermoelectric device206 on and off may be controlled, for example, under operation of theintelligent control200. For example, theintelligent control200 may be configured to control the percentage of “on” time versus “off” time (i.e., the duty cycle) duringpulse width modulation216 of thepower210 provided to thethermoelectric device206. Alternatively, avariable DC218 level may be used to power thethermoelectric device206. Using for example, a linear drive current aspower210input204 into thethermoelectric device206 under control of theintelligent control200, thethermoelectric device206 may be linearly driven to control the liquid to ice or ice toliquid phase change208 in theice mold224 of theicemaker220. One ormore sensors202 positioned in locations at theicemaker220, as previously described, may be used to monitor thetemperature228 and provide feedback to theintelligent control200 to provide correction to theinputs204 from the power sources210 (e.g.,voltage212,amperage214,pulse width modulation216, variable DC218). For example, since the liquid to ice phase change or the ice toliquid phase change208 requires a certain amount of energy for the change to occur, this energy may be detected by one ormore sensors202 positioned at one or more locations at the icemaker220 (e.g.,heat sink222,ice mold224,substrate226,conductor60, etc.) to determine thetemperature228 and provide information to theintelligent control200 based oninputs204 to thethermoelectric device206. For example, thepower210inputs204 such asvoltage212,amperage214,pulse width modulation216 orvariable DC218 may be controlled or corrected depending upon the phase of the liquid to ice stage or ice toliquid stage208. In one aspect of the disclosure, in a liquid toice phase change208, thetemperature228 of the liquid in theice mold224 may remain generally flat although theinputs204 to thethermoelectric device206 may increase at least until theentire ice mold224 is frozen (i.e., all the water in the mold is frozen) and ice is formed. Alternatively, when ice in contact with a surface of theice mold224 is being changed from ice to liquid, thetemperature228 of theice mold224 may be fairly level despite the increase in inputs204 (e.g.,power210 to the thermoelectric device206) until the phase change occurs. In this manner,power210 provided as aninput204 to thethermoelectric device206 may be monitored (e.g. voltage212,amperage214,pulse width modulation216 orvariable DC218 may be monitored) to determine the phase of the liquid to ice or ice toliquid phase change208 in theice mold224 of theicemaker220.Temperature228 taken by one ormore sensors202 positioned at, for example, aheat sink222 in thermal contact with theice mold224 or asubstrate226 may be used to provide a feedback response to theintelligent control200 for correcting or adjusting theinputs204 to thethermoelectric device206. Thus, using at least in part, existing features and inputs to athermoelectric device50, a low energy system for monitoring the ice to liquid or liquid toice phase change208 for anicemaker220 chilled or warmed by athermoelectric device206 is provided.
• The foregoing description has been presented for the purposes of illustration and description. It is not intended to be an exhaustive list or limit the invention to the precise forms disclosed. It is contemplated that other alternative processes and methods obvious to those skilled in the art are considered included in the invention. The description is merely examples of embodiments. For example, the inputs to the thermoelectric device (e.g., fluid flow or air flow rates acrossheat sink56,power210inputs204 controlled by intelligent control200) may be varied according to type of cycle (ice production, fresh ice production, ice harvesting) being conducted and the desired performances for the refrigerator. It is understood that any other modifications, substitutions, and/or additions may be made, which are within the intended spirit and scope of the disclosure. From the foregoing, it can be seen that the exemplary aspects of the disclosure accomplishes at least all of the intended objectives.

Claims (20)

1. A refrigerator that has a fresh food compartment, a freezer compartment, and a door that provides access to the fresh food compartment, the refrigerator comprising:

an icemaker mounted remotely from the freezer compartment, the icemaker including an ice mold with an icemaking cycle having a liquid to ice phase change;

a thermoelectric device, the thermoelectric device having a cold side;

a controller in operable communication with an input to the thermoelectric device;

a sensor in operable communication with the input to the thermoelectric device and the controller;

a temperature feedback response from the input to the thermoelectric device for monitoring the liquid to ice phase change of the icemaking cycle; and

a substrate having high thermal conductivity in thermal contact with the cold side of the thermoelectric device.

2. The refrigerator ofclaim 1 wherein the input comprises a voltage provided to the thermoelectric device, wherein the feedback response from the voltage input determines the liquid to ice phase change of the icemaking cycle.

3. The refrigerator ofclaim 1 wherein the input comprises an amperage provided to the thermoelectric device, wherein the feedback response from the amperage input determines the liquid to ice phase change of the icemaking cycle.

4. The refrigerator ofclaim 1 wherein the input comprises a frequency of a pulse-width modulation (PWM) provided by the controller, wherein the feedback response from the frequency of the PWM determines the liquid to ice phase change of the icemaking cycle.

5. The refrigerator ofclaim 1 wherein the input comprises a linear drive current for providing a variable (DC) level, wherein the feedback response from the linear drive current providing the variable DC level input determines the liquid to ice phase change of the icemaking cycle.

6. The refrigerator ofclaim 1 whereby the thermoelectric device has a warm side, and further comprising a heat sink in thermal contact with the warm side of the thermoelectric device, the sensor in thermal communication with the heat sink for providing a temperature reading to the controller for determining the liquid to ice phase change of the icemaking cycle.

7. The refrigerator ofclaim 1 further comprising a substrate in thermal contact with the cold side of the thermoelectric device, the sensor in thermal communication with the substrate for providing a temperature reading to the controller for determining the liquid to ice phase change of the icemaking cycle.

8. The refrigerator ofclaim 6 wherein the controller correlates the temperature reading from the heat sink with the input to provide the feedback response to make a correction to the input based on the liquid to ice phase change of the icemaking cycle.

9. An icemaker comprising:

an ice mold with an icemaking cycle having a liquid to ice phase change;

a thermoelectric device, the thermoelectric device having a cold side;

an input to the thermoelectric device;

a controller in operable communication with the thermoelectric device and the input;

a sensor in operable communication with the thermoelectric device;

a temperature feedback response from the thermoelectric device to the controller for monitoring the liquid to ice phase change of the icemaking cycle; and

a substrate in thermal contact with the cold side of the thermoelectric device.

10. The icemaker ofclaim 9 wherein the input comprises a voltage provided to the thermoelectric device, wherein the feedback response from the voltage input determines the liquid to ice phase change of the icemaking cycle.

11. The icemaker ofclaim 9 wherein the input comprises an amperage provided to the thermoelectric device, wherein the feedback response from the amperage input determines the liquid to ice phase change of the icemaking cycle.

12. The icemaker ofclaim 9 in combination with a refrigerator that has a fresh food compartment, a freezer compartment, and a door that provides access to the fresh food compartment.

13. The icemaker ofclaim 12 wherein the icemaker further comprises an ice to liquid phase change monitored to determine an ice harvesting cycle or a fresh ice production cycle.

14. The icemaker ofclaim 9 wherein the controller correlates a temperature reading from the ice mold with the input to provide the feedback response to make a correction to the input based on the liquid to ice phase change of the icemaking cycle.

15. A method for cooling in a refrigerator that has a fresh food compartment, a freezer compartment, and a door that provides access to the fresh food compartment, the method comprising:

providing an icemaker mounted remotely from the freezer compartment, the icemaker including an ice mold with an icemaking cycle having a liquid to ice phase change;

locating a thermoelectric device, the thermoelectric device having a cold side;

wherein a substrate is in thermal contact with the cold side of the thermoelectric device;

controlling an input to the thermoelectric device using a controller in operable communication with the input and the thermoelectric device;

monitoring a feedback response from the input to the thermoelectric device for determining the liquid to ice phase change of the icemaking cycle; and

controlling a voltage input to the thermoelectric device and monitoring the feedback response from the voltage input to determine the liquid the ice phase change of the icemaking cycle.

16. The method ofclaim 15 further comprising controlling a voltage input to the thermoelectric device and monitoring the feedback response from the voltage input to determine the liquid to ice phase change of the icemaking cycle.

17. The method ofclaim 15 further comprising controlling an amperage input to the thermoelectric device and monitoring the feedback response from the amperage input to determine the liquid to ice phase change of the icemaking cycle.

18. The method ofclaim 15 whereby the thermoelectric device has a warm side, said method further comprising reading a temperature from a heat sink in thermal contact with the warm side of the thermoelectric device for determining the liquid to ice phase change of the icemaking cycle.

19. The method ofclaim 15 further comprising reading a temperature from the ice mold in thermal contact with the cold side of the thermoelectric device for determining the liquid to ice phase change of the icemaking cycle.

20. The method ofclaim 19 further comprising correlating the temperature reading from the ice mold with the input to provide the feedback response to make a correction to the input based on the liquid to ice phase change of the icemaking cycle.

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