CN114364935A

CN114364935A - Evaporator assembly for ice making apparatus

Info

Publication number: CN114364935A
Application number: CN202080063545.0A
Authority: CN
Inventors: 彼得·艾伦·克伦肖·布里格斯; 奥斯汀·B·康纳; 贾斯汀·泰勒·布朗; 布伦特·奥尔登·容格
Original assignee: Qingdao Haier Refrigerator Co Ltd; Haier Smart Home Co Ltd; Haier US Appliance Solutions Inc
Current assignee: Qingdao Haier Refrigerator Co Ltd; Haier Smart Home Co Ltd; Haier US Appliance Solutions Inc
Priority date: 2019-09-12
Filing date: 2020-09-07
Publication date: 2022-04-15
Also published as: US20210080159A1; WO2021047463A1; EP4030126A1; EP4030126A4

Abstract

An ice-making assembly includes an ice-making mold (200) defining a mold cavity and an evaporator assembly (202) thermally coupled to the ice-making mold (200). A compressor (114) is operatively connected to the refrigerant circuit for circulating a flow of refrigerant in the refrigerant circuit to cool the evaporator assembly (202) and the ice-making molds (200). The evaporator assembly (202) includes a primary evaporator tube (230) and a heat enhancement structure (232) (e.g., an inner tube and/or a foamy copper structure) disposed therein to increase refrigerant side surface area. The primary evaporator tube (230) is deformed into a non-circular cross-sectional shape and soldered or brazed to the top wall of the ice-making mold (200).

Description

Evaporator assembly for ice making apparatus

Technical Field

The present invention relates generally to ice makers, and more particularly to an evaporator assembly for cooling an ice mold of an ice maker.

Background

In domestic and commercial applications, ice is typically made as solid ice pieces, such as crescent shaped pieces of ice or generally rectangular shaped pieces of ice. The shape of such ice cubes is generally determined by the container holding the water during freezing. For example, an ice maker can receive liquid water, which can freeze within the ice maker, forming ice cubes. In particular, some ice-making machines include a freezing mold that defines a plurality of cavities. The plurality of cavities may be filled with liquid water, and such liquid water may freeze to form solid ice cubes within the plurality of cavities. Typical solid ice cubes can be relatively small to accommodate a variety of uses, such as temporary refrigeration and rapid cooling of liquids in various sizes.

Although typical solid ice cubes may be useful in many situations, in some situations distinct or unique shapes of ice cubes may be desired. For example, it has been demonstrated in practice that relatively large ice cubes or spherical ice (e.g., greater than two inches in diameter) melt slower than typical ice cube sizes/shapes. In some spirits or cocktails, it may be more desirable for the ice to melt more slowly. At the same time, such ice cubes or spheroids may give the user a unique or high-end impression.

In recent years, ice makers have been developed that form larger ice blanks by avoiding trapping impurities and gases within the blank. These appliances further use precise temperature control to avoid the formation of a dull or cloudy appearance on the outer surface of the ice blank (e.g., during rapid freezing of the ice cubes). In addition, to ensure that the formed or finished ice cubes or spheroids are substantially transparent, many systems form solid ice billets that are much larger (e.g., 50% larger in mass or volume) than the desired finished ice cubes or spheroids. In addition to the general inefficiency, this can greatly increase the time and energy required to melt or form the initial ice slab into final ice cubes or spheroids.

With conventional ice-making assemblies that form large ice parisons, one often encounters the problem of keeping the ice-making mold cool enough to freeze the entire thickness of the large ice parison, particularly toward the bottom of the ice parison or the area furthest from the evaporator. Accordingly, there is a need for further improvements in the field of ice making. In particular, it would be particularly advantageous for the evaporator assembly to be capable of quickly and efficiently cooling the ice-making mold of the ice-making assembly.

Disclosure of Invention

Aspects and advantages of the invention will be set forth in part in the description which follows, or may be obvious from the description, or may be learned by practice of the invention.

In one exemplary aspect of the present invention, there is provided an ice making assembly, including: an ice-making mold defining a mold cavity, and an evaporator assembly thermally coupled to the ice-making mold. The evaporator assembly includes a primary evaporator tube in direct contact with the ice-making mold and a thermal enhancement structure located within the primary evaporator tube.

In another exemplary aspect of the present invention, a method of making an ice-making assembly is provided. The method comprises the following steps: disposing a thermal enhancement structure within the primary evaporator tube; pressing the primary evaporator tube into a non-circular shape to increase thermal contact between the thermal enhancement structure and the primary evaporator tube; and attaching the primary evaporator tube to an ice-making mold defining a mold cavity.

These and other features, aspects, and advantages of the present technology 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.

Drawings

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

Fig. 1 is a side plan view of an ice maker according to an exemplary embodiment of the present invention;

FIG. 2 is a schematic diagram of an ice-making assembly according to an exemplary embodiment of the present invention;

FIG. 3 is a simplified perspective view of an ice-making assembly according to an exemplary embodiment of the present invention;

FIG. 4 is a schematic cross-sectional view of the exemplary ice-making assembly of FIG. 3;

FIG. 5 is a schematic cross-sectional view of a portion of the exemplary ice-making assembly of FIG. 3 during an ice-making operation;

fig. 6 is a bottom perspective view of an ice-making mold and evaporator assembly according to an exemplary embodiment of the present invention;

fig. 7 is a top perspective view of the exemplary ice-making mold and evaporator assembly of fig. 6 according to an exemplary embodiment of the invention;

FIG. 8 is a cross-sectional view of a primary evaporator tube of the exemplary evaporator assembly of FIG. 6 according to an exemplary embodiment of the present invention;

FIG. 9 is a cross-sectional view of a primary evaporator tube of the exemplary evaporator assembly of FIG. 6 according to another exemplary embodiment of the present invention;

fig. 10 is a method of making an evaporator assembly of an ice-making assembly according to an exemplary embodiment of the present invention.

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

Detailed Description

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. It is therefore intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

The terms "first," "second," and "third" are used interchangeably herein to distinguish one element from another and are not intended to denote the exact position or importance of the various elements. "upstream" and "downstream" refer to relative flow directions with respect to fluid flow in a fluid pathway. For example, "upstream" refers to the direction of flow of fluid out of it, while "downstream" refers to the direction of flow of fluid into it. Likewise, "or" is generally intended to mean 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, may be 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 cases, the approximating language may correspond to the precision of an instrument for measuring the value. For example, approximating language may refer to a range of 10% margin.

Referring again to the drawings, FIG. 1 provides a side plan view of an ice maker 100 that includes an ice making assembly 102. Fig. 2 provides a schematic illustration of the ice-making assembly 102. Fig. 3 provides a simplified perspective view of ice-making assembly 102. In general, the ice maker 100 includes a case 104 (e.g., a heat insulating case) and defines a vertical direction V, a lateral direction, and a lateral direction, which are orthogonal to each other. The lateral direction and the transverse direction are generally understood to be the horizontal direction H.

As shown, the cabinet 104 defines one or more refrigerated compartments, such as a freezer compartment 106. In certain embodiments, such as the embodiment shown in fig. 1, ice maker 100 is understood to be a stand-alone freezer appliance or as part of a stand-alone freezer appliance. It is also recognized that additional or alternative embodiments may be provided on other refrigeration appliances. For example, the benefits of the present invention may be applicable to any type or style of refrigeration appliance, including a freezer compartment (e.g., overhead refrigeration appliances, floor-mounted refrigeration appliances, and side-by-side refrigeration appliances). Accordingly, the description herein is for illustrative purposes only and is not intended to limit any particular compartment configuration in any respect.

The ice maker 100 generally includes an ice making assembly 102 disposed on or in a freezer compartment 106. In some embodiments, ice maker 100 includes a door 105 that is rotatably attached to bin 104 (e.g., at the top of the bin). It should be understood that the door 105 may selectively cover the opening defined by the box 104. For example, on the bin 104, the door 105 may be rotated between an open position (not shown) that allows access to the freezer compartment 106 and a closed position (fig. 2) that restricts access to the freezer compartment 106.

A user interface panel 108 is provided for controlling the mode of operation. For example, the user interface panel 108 may include a plurality of user inputs (not labeled), such as a touch screen or a key interface, for selecting a desired operating mode. The operation of the ice maker 100 may be regulated by a controller 110 operatively connected to a user interface panel 108 or various other components, as described below. User interface panel 108 provides a user with a variety of options for manipulating the operation of ice maker 100 (e.g., selections regarding compartment temperature, ice making speed, or other various options). The controller 110 can operate the ice maker 100 or various components of the ice making assembly 102 in response to a user manipulating the user interface panel 108 or one or more sensor signals.

The controller 110 can include a memory (e.g., non-transitory memory) and one or more microprocessors, central processing units, or the like, such as general or special purpose microprocessors that can be used to execute programming instructions or micro-control code associated with the operation of the ice maker 100. The memory may be a random access memory, such as DRAM, or a read only memory, such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in the memory. The memory may be a separate component from the processor or may be contained within the processor. Alternatively, the controller 110 may not use a microprocessor (e.g., use a combination of discrete analog or digital logic circuits, such as switches, amplifiers, integrators, comparators, flip-flops, gates, etc., to perform control functions rather than relying on software).

The controller 110 may be located at various positions of the ice maker 100. In an alternative embodiment, the controller 110 is located in the user interface panel 108. In other embodiments, the controller 110 can be located at any suitable location within the ice maker 100, such as within the bin 104. Input/output ("I/O") signals may be sent between the controller 110 and various operational components of the ice maker 100. For example, the user interface panel 108 may communicate with the controller 110 via one or more signal lines or a shared communication bus.

As shown, the controller 110 may be in communication with and may control the operation of various components of the ice-making assembly 102. For example, various valves, switches, etc. may be actuated based on commands from the controller 110. Further, as described above, the user interface panel 108 may be in communication with the controller 110. Thus, the various modes may be automatically operated according to user input or by a command of the controller 110.

Generally, as shown in fig. 3 and 4, the ice maker 100 includes a hermetic refrigeration system 112 for performing a vapor compression cycle to cool water within the ice maker 100 (e.g., within the freezer compartment 106). The hermetic refrigeration system 112 includes a compressor 114, a condenser 116, an expansion device 118, and an evaporator 120, which are in series fluid communication and filled with a refrigerant. As will be appreciated by those skilled in the art, the sealed refrigeration system 112 may include additional components (e.g., one or more reversing flow valves or an additional evaporator, compressor, expansion device, or condenser). Further, at least one component (e.g., evaporator 120) is thermally coupled (e.g., thermally conductive) to the ice-making mold or ice-making mold component 130 (fig. 3) to facilitate, for example, cooling of the mold component 130 during ice-making operations. Optionally, an evaporator 120 is mounted within the freezer compartment 106, as shown in FIG. 1.

Within the hermetic refrigeration system 112, the gaseous refrigerant flows into a compressor 114, which operates to increase the pressure of the refrigerant. This compression of the refrigerant raises its temperature, which is lowered by the passage of gaseous refrigerant through the condenser 116. Within the condenser 116, heat is exchanged with ambient air to cool and condense the refrigerant into a liquid state.

An expansion device 118 (e.g., a mechanical valve, a capillary tube, an electronic expansion valve, or other restriction device) receives liquid refrigerant from the condenser 116. From the expansion device 118, the liquid refrigerant enters the evaporator 120. Upon exiting the expansion device 118 and entering the evaporator 120, the liquid refrigerant drops in pressure and evaporates. The evaporator 120 is cooler relative to the freezer compartment 106 due to the pressure drop and phase change of the refrigerant. Thus, cooled water and ice or air are generated and the icemaker 100 or the freezing chamber 106 is cooled. Thus, the evaporator 120 serves as a heat exchanger for transferring heat of water or air thermally connected to the evaporator 120 to the refrigerant flowing through the evaporator 120.

Optionally, as described in more detail below, one or more reversing valves (e.g., disposed between the compressor 114 and the condenser 116) may be provided to selectively redirect refrigerant through a bypass line connecting the one or more reversing valves to a point in the fluid circuit downstream of the expansion device 118 and upstream of the evaporator 120. In other words, the one or more reversing valves may allow refrigerant to selectively bypass the condenser 116 and the expansion device 120.

In additional or alternative embodiments, ice maker 100 further includes a valve 122 for regulating the flow of liquid water to ice making assembly 102. For example, the valve 122 may be selectively adjustable between an open position and a closed position. In the open state, valve 122 allows liquid water to flow into ice-making assembly 102 (e.g., to water dispenser 132 or water reservoir 134 of ice-making assembly 102). In contrast, in the closed state, valve 122 prevents liquid water from flowing to ice-making assembly 102.

In some embodiments, the ice maker 100 also includes a separate compartment cooling system 124 (e.g., separate from the hermetic refrigeration system 112) that is generally used to draw heat from the freezer compartment 106. For example, the discrete compartment cooling system 124 may include a respective sealed refrigeration circuit (e.g., including a unique compressor, condenser, evaporator, and expansion device) or air handler (e.g., axial fan, centrifugal fan, etc.) to facilitate the flow of cool air in the freezer compartment 106.

Referring again to fig. 3 and 4, fig. 4 provides a schematic cross-sectional view of the ice-making assembly 102. As shown, the ice making assembly 102 includes a mold assembly 130 defining a mold cavity 136 in which an ice slab 138 may be formed. Alternatively, mold assembly 130 may define a plurality of mold cavities 136 spaced apart from one another (e.g., perpendicular to vertical direction V). One or more portions of the sealed refrigeration system 112 may be thermally coupled to the mold assembly 130. In particular, the evaporator 120 may be disposed on or in contact with (e.g., in thermally conductive contact with) a portion of the mold assembly 130. In use, evaporator 120 may selectively draw heat from mold cavity 136, as will be described further below. In addition, a water distributor 132 disposed below mold assembly 130 may selectively direct a flow of water into mold cavities 136. Generally, water distributor 132 includes a water pump 140 and at least one nozzle 142 that faces mold cavity 136 (e.g., vertically). In embodiments where mold assembly 130 defines a plurality of discrete mold cavities 136, water distributor 132 may include a plurality of nozzles 142 or fluid pumps vertically aligned with the plurality of mold cavities 136. For example, each mold cavity 136 may be vertically aligned with a separate nozzle 142.

In some embodiments, water trough 134 is disposed below the ice-making mold (e.g., directly below mold cavity 136 in vertical direction V). Water channel 134 includes a solid channel body that is impervious to water and may define a vertical opening 145 and an interior volume 146 in fluid communication with mold cavity 136. After assembly, excess fluid, such as water, falling from mold cavity 136 may enter interior volume 146 of water tank 134 through vertical opening 145. In certain embodiments, one or more portions of the water dispenser 132 are located within the sink 134 (e.g., within the interior volume 146). For example, the water pump 140 may be mounted within the water tank 134 in fluid communication with the interior volume 146. Accordingly, the water pump 140 may selectively draw water from the interior volume 146 (e.g., dispensed from the nozzle 142). The nozzle 142 may extend from the water pump 140 (e.g., vertically) through the interior volume 146.

In an alternative embodiment, a guide ramp 148 is provided between the mold assembly 130 and the water trough 134 along the vertical direction V. For example, guide ramp 148 may include a ramp that extends at a negative angle (e.g., with respect to horizontal) from a location below mold cavity 136 to another location spaced (e.g., horizontally) from water trough 134. In some such embodiments, the guide slopes 148 extend above the ice bank 150 or terminate above the ice bank 150. Additionally or alternatively, guide ramp 148 may define a perforated portion 152 that is vertically aligned, for example, between mold cavity 136 and nozzle 142 or between mold cavity 136 and interior volume 146. Generally, one or more holes are defined through the guide ramp 148 at the perforated portion 152. As such, a fluid such as water may generally pass through perforated portion 152 of guide ramp 148 (e.g., in a vertical direction between mold cavity 136 and interior volume 146).

As shown, the ice bank 150 generally defines a storage volume 154 and can be disposed below the mold assembly 130 and the mold cavity 136. The ice bank 138 formed within the mold cavity 136 can be ejected from the mold assembly 130 and subsequently stored within the storage volume 154 of the ice bank 150 (e.g., within the freezing chamber 106). In some such embodiments, the ice bank 150 is disposed within the freezing chamber 106 and horizontally spaced apart from the water tank 134, the water dispenser 132, or the mold assembly 130. The guide slope 148 may span a horizontal distance between the mold assembly 130 and the ice bank 150. As the ice parisons 138 are lowered or dropped from the mold cavities 136, the ice parisons 138 can be moved (e.g., under the force of gravity) toward the ice bank 150.

Referring now to fig. 4 and 5 in general, an exemplary ice making operation of the ice making assembly 102 will be described. As shown, the mold assembly 130 is made of a discrete, thermally conductive ice-making mold 160 and an insulating sleeve 162. Typically, the insulation sleeve 162 extends downward from (e.g., directly from) the thermally conductive ice-making mold 160. For example, the insulation sleeve 162 may be secured to the thermally conductive ice-making mold 160 by one or more suitable adhesives or attachment fasteners (e.g., bolts, snap locks, mating splines, etc.) disposed or formed between the thermally conductive ice-making mold 160 and the insulation sleeve 162.

The thermally conductive ice-making mold 160 may define a mold cavity 136 with an insulating sleeve 162. For example, the thermally conductive ice making mold 160 may define an upper portion 136A of the mold cavity 136, while the insulating sleeve 162 defines a lower portion 136B of the mold cavity 136. An upper portion 136A of mold cavity 136 may extend between a watertight top end 164 and an open bottom end 166. Additionally or alternatively, an upper portion 136A of mold cavity 136 can be curved (e.g., hemispherical) and maintained in open fluid communication with a lower portion 136B of mold cavity 136. Lower portion 136B of mold cavity 136 may be a vertically open channel that is aligned (e.g., in vertical direction V) with upper portion 136A of mold cavity 136. Thus, the mold cavity 136 may extend in a vertical direction between the mold opening 168 at the bottom or bottom surface 170 of the insulation sleeve 162 and the top end 164 within the thermally conductive ice making mold 160. In some such embodiments, mold cavity 136 defines a constant diameter or horizontal width from lower portion 136B to upper portion 136A. Upon assembly, (e.g., after flowing through the bottom opening defined by the sleeve 162), a fluid such as water may flow through the lower portion 136B of the mold cavity 136 to the upper portion 136A of the mold cavity 136.

The thermally conductive ice-making mold 160 and the insulation sleeve 162 are at least partially made of two different materials. The thermally conductive ice-making mold 160 is typically made of a thermally conductive material (e.g., a metal such as copper, aluminum, or stainless steel, including alloys thereof), while the insulating sleeve 162 is typically made of an insulating material (e.g., an insulating polymer such as synthetic silicone that can be used at sub-freezing temperatures without significant degradation). According to an alternative embodiment, the insulating sleeve 162 may be made of polyethylene terephthalate (PET) plastic or any other suitable material. In some embodiments, the thermally conductive ice-making mold 160 is made of a material having greater water surface adhesion than the material of the insulation sleeve 162. Water frozen within mold cavity 136 is prevented from extending horizontally along bottom surface 170 of insulating sleeve 162.

At the same time, it is beneficial to prevent the ice bank within mold cavity 136 from popping out beyond the boundaries of mold cavity 136. Additionally, if multiple mold cavities 136 are defined within mold assembly 130, ice-making assembly 102 can facilitate preventing a contiguous layer of ice from forming along bottom surface 170 of insulating sleeve 162 between separated mold cavities 136 (and the ice slab therein). Further, the present embodiment is advantageous to ensure even heat distribution on the ice blank within mold cavity 136. In this way, the ice blank can be prevented from cracking or forming dimples in the bottom of the ice blank.

In some embodiments, the unique materials of the thermally conductive ice making mold 160 and the insulation sleeve 162 each extend to the surfaces defining the upper portion 136A and the lower portion 136B of the mold cavity 136. In particular, a material having a relatively high water adhesion may define the boundaries of upper portion 136A of mold cavity 136, while a material having a relatively low water adhesion may define the boundaries of lower portion 136B of mold cavity 136. For example, the surface of insulating sleeve 162 that bounds lower portion 136B of mold cavity 136 may be made of an insulating polymer (e.g., silicone). The surfaces of thermally conductive mold cavity 136 that bound upper portion 136A of mold cavity 136 may be made of a thermally conductive metal (e.g., aluminum or copper). In some such embodiments, the thermally conductive metal of the thermally conductive ice-making mold 160 may extend along (e.g., entirely) the upper portion 136A.

While the foregoing illustrates an exemplary mold assembly 130, it is understood that variations and modifications of the mold assembly 130 are possible within the scope of the invention. For example, the size, number, location, and geometry of mold cavities 136 may vary. Additionally, according to alternative embodiments, a thermal insulating film may be provided extending along the boundary of the upper portion 136A of the cavity 136, for example, along the inner surface of the thermally conductive ice-making mold 160 at the upper portion 136A of the cavity 136. Indeed, various aspects of the invention may be modified and practiced in different ice making appliances or processes without departing from the scope of the invention.

In some embodiments, one or more sensors are mounted on or within ice-making mold 160. For example, the temperature sensor 180 may be installed near the ice making mold 160. The temperature sensor 180 may be electrically connected to the controller 110 for detecting the temperature inside the ice making mold 160. The temperature sensor 180 may be made as any suitable temperature sensing device, such as a thermocouple, thermistor, or the like. Although the temperature sensor 180 is described herein as being mounted on the ice-making mold 160, it should be understood that the temperature sensor may be disposed at any other suitable location for providing data indicative of the temperature of the ice-making mold 160, according to alternative embodiments. For example, the temperature sensor 180 may be mounted to a coil of the evaporator 120 or at any other suitable location within the ice maker 100.

As shown, the controller 110 may be in communication (e.g., electrical communication) with one or more portions of the ice-making assembly 102. In some embodiments, the controller 110 is in communication with one or more fluid pumps (e.g., water pump 140), compressor 114, flow regulating valves, and the like. The controller 110 may be configured to initiate separate ice making and ice releasing operations. For example, controller 110 may alternate the injection of fluid sources into mold cavities 136 and the release or harvest of ice, as will be described in greater detail below.

During an ice making operation, controller 110 can activate or command water dispenser 132 to cause an ice making spray fluid (e.g., as indicated by arrow 184) to flow through nozzle 142 and into mold cavity 136 (e.g., through mold opening 168). The controller 110 may also command the hermetic refrigeration system 112 (e.g., at the compressor 114) (fig. 3) to cause the refrigerant to pass through the evaporator 120 and absorb heat from within the mold cavity 136. As the water of the icemaking jets 184 strikes the mold assembly 130 in the mold cavity 136, a portion of the water may gradually freeze from the top end 164 to the bottom end 166. Excess water (e.g., water in the mold cavity 136 that does not freeze upon contact with the mold assembly 130 or frozen portions therein) and impurities in the ice-making spray fluid 184 can fall from the mold cavity 136 and, for example, into the water tank 134.

Once ice bank 138 is formed within mold cavity 136, an ice release or harvest process may be performed in accordance with embodiments of the present invention. Specifically, referring again to fig. 3, the seal system 112 may further include a bypass conduit 190 fluidly connected to the refrigeration circuit or seal system 112 for flowing a portion of the refrigerant flow around the condenser 116. In this way, the temperature of the refrigerant flow entering the evaporator 120 can be precisely adjusted by selectively adjusting the amount of relatively hot refrigerant flow exiting the compressor 114 and bypassing the condenser 116.

Specifically, according to the illustrated embodiment, the bypass conduit 190 extends from a first junction 192 to a second junction 194 within the sealing system 112. First junction 192 is located between compressor 114 and condenser 116, e.g., downstream of compressor 114 and upstream of condenser 116. In contrast, the second junction 194 is located between the condenser 116 and the evaporator 120, e.g., downstream of the condenser 116 and upstream of the evaporator 120. Further, although according to the illustrated embodiment, second junction 194 is located downstream of expansion device 118, second junction 194 may be located upstream of expansion device 118. When connected in this manner, the bypass conduit 190 provides a path through which a portion of the refrigerant flow may pass from the compressor 114 directly to a location immediately upstream of the evaporator 120 to raise the temperature of the evaporator 120.

Notably, if substantially all of the refrigerant flow is diverted through the bypass conduit 190 and through the compressor 114 while the ice making mold 160 is still very cold (e.g., below 10 ° F or 20 ° F), the evaporator temperature may suddenly increase causing the ice bank 138 to be thermally shocked, possibly resulting in cracking of the ice bank 138. Thus, the controller 110 can implement a method of slowly adjusting or precisely controlling the evaporator temperature to achieve the desired mold temperature profile and harvest release time to prevent ice bank 138 from cracking.

In this regard, for example, the bypass conduit 190 may be fluidly connected to the seal system 112 using a flow regulation device 196. In particular, the flow regulation device 196 may be used to connect the bypass conduit 190 to the seal system 112 at the first junction 192. In general, the flow regulating device 196 may be any device suitable for regulating the flow of refrigerant through the bypass conduit 190. For example, in accordance with an exemplary embodiment of the present invention, the flow regulating device 196 is an electronic expansion device that can selectively divert a portion of the refrigerant flow exiting the compressor 114 into the bypass conduit 190. According to yet another embodiment, the flow regulating device 196 may be a servo motor control valve for regulating the flow of refrigerant through the bypass conduit 190. According to yet another embodiment, the flow regulating device 196 may be a three-way valve installed at the first junction 192 or a solenoid valve operatively connected along the bypass conduit 190.

According to an exemplary embodiment of the invention, controller 110 may initiate an ice release or harvest process to eject ice bank 138 from mold cavity 136. Specifically, for example, the controller 110 may first stop or block the ice making ejection fluid 184 by de-energizing the water supply pump 140. Next, the controller 110 may adjust the operation of the sealing system 112 to slowly increase the temperature of the evaporator 120 and the ice making mold 160. Specifically, by increasing the temperature of the evaporator 120, the mold temperature of the ice-making mold 160 is also increased, thereby facilitating partial melting or release of the ice slab 138 from the mold cavity.

According to an exemplary embodiment, the controller 110 may be operatively connected to a flow regulating device 196 for regulating the flow of the refrigerant flow through the bypass conduit 190. Specifically, according to one exemplary embodiment, the controller 110 may be used to obtain the mold temperature of the mold body using the temperature sensor 180. Although "mold temperature" is used herein, it should be understood that temperature sensor 180 may measure any suitable temperature within ice maker 100 indicative of mold temperature and may be used to facilitate improved harvesting of ice parisons 138.

The controller 110 may also adjust the flow adjustment device 196 to control the flow of refrigerant based in part on the measured mold temperature. For example, according to one exemplary embodiment, the flow adjustment device 196 may be adjusted such that the rate of change of the mold temperature does not exceed a predetermined rate threshold. For example, the predetermined rate threshold may be any suitable rate of temperature change above which the ice bank 138 may be thermally cracked. For example, according to one exemplary embodiment, the predetermined rate threshold may be about 1 ° F per minute, about 2 ° F per minute, about 3 ° F per minute, or higher. According to an exemplary embodiment, the predetermined rate threshold may be less than 10 ° F per minute, less than 5 ° F per minute, less than 2 ° F per minute, or lower. In this manner, flow regulating device 196 regulates the rate of temperature change of ice bank 138, thereby preventing thermal cracking.

Generally, the sealing system 112 and method of operation described herein are intended to accommodate temperature variations of ice bank 138 to prevent thermal cracking. However, while specific control algorithms and system configurations have been described, it should be understood that variations and modifications of such systems and methods may be made in accordance with alternative embodiments without departing from the scope of the present invention. For example, the specific plumbing connections of the bypass conduit 190 may vary, the type or location of the flow regulation device 196 may vary, and different control methods may be used without departing from the scope of the present invention. Additionally, depending on the size and shape of ice billets 138, the predetermined rate threshold and the predetermined temperature threshold may be adjusted to prevent cracking of a particular ice billet 138 or otherwise facilitate an improvement in the harvesting process.

Referring now specifically to fig. 6 and 7, an exemplary ice-making mold 200 and evaporator assembly 202 that may be used with the ice maker 100 will be described in accordance with an exemplary embodiment of the present invention. Specifically, for example, the ice-making mold 200 may be used as the mold assembly 130, and the evaporator assembly 202 may be used as the evaporator 120 of the sealed cooling system 112. Although the ice-making mold 200 and evaporator assembly 202 are described herein with respect to the ice-making appliance 100, it should be understood that the ice-making mold 200 and evaporator assembly 202 may be used in any other suitable ice-making application or appliance.

As shown, the ice-making mold 200 generally includes a top wall 210 and a plurality of side walls 212 depending from the top wall 210 and extending downwardly from the top wall 210. More specifically, according to the illustrated embodiment, the ice-making mold 200 includes eight side walls 212 including an inclined portion 214 extending away from the top wall 210 and a vertical portion 216 extending substantially vertically downward from the inclined portion 214. As such, when viewed in a horizontal plane, the top wall 210 and the plurality of side walls 212 form a mold cavity 218 having an octagonal cross-section. Additionally, each of the plurality of sidewalls 212 may be spaced apart by a gap 220 that extends in a substantially vertical direction. In this way, the plurality of sidewalls 212 may move relative to each other and serve as spring fingers so that the ice making mold 200 may be deflected to some extent during the ice making process. It is noted that such elasticity of the ice-making mold 200 helps to improve ice formation and reduce the possibility of cracking.

In general, the ice-making mold 200 may be made of any suitable material in any suitable manner that provides sufficient thermal conductivity to transfer heat to the evaporator assembly 202 to facilitate the ice-making process. According to an exemplary embodiment, the ice-making mold 200 is made of one piece of copper plate. In this regard, for example, a flat copper plate of constant thickness may be machined to define the top wall 210 and the side walls 212. Sidewall 212 may then be bent to form a mold cavity 218 of a desired shape, such as the octagonal or gem-stone shape described above. In this way, the top wall 210 and the side wall 212 can be formed to have substantially the same thickness without requiring complicated and expensive machining processes.

According to an exemplary embodiment of the present invention, the evaporator assembly 202 is installed to be in direct contact with the top wall 210 of the ice making mold 200. Additionally, the evaporator assembly 202 may not be in direct contact with the sidewall 212. It is contemplated that this may prevent restricting movement of the sidewall 212, for example, reducing the likelihood of ice cracking. Notably, when the evaporator assembly 202 is mounted only on the top wall 210, the heat conduction path to each of the plurality of side walls 212 is a joint or connection structure where the side walls 212 join the top wall 210. Therefore, it may be desirable to increase the sidewall width 222 as much as possible to improve thermal conductivity. For example, the sidewall width 222 may be between about 0.5 inches and 1.5 inches, between about 0.7 inches and 1 inch, or about 0.8 inches. Such a sidewall width 222 facilitates conduction of thermal energy to the bottom end of each of the plurality of sidewalls 212.

In addition, to improve the thermal contact between the evaporator assembly 202 and the ice making mold 200, it is desirable to make the top wall relatively large. Thus, according to an exemplary embodiment, top wall 210 may define a top width 224 and mold cavity 218 may define a maximum width 226. According to an exemplary embodiment, top width 224 is greater than about 50% of maximum width 226. In other embodiments, top width 224 may be greater than about 60% of maximum width 226, or greater than about 70% of maximum width 226, or greater than about 80% of maximum width 226, or greater. Additionally or alternatively, top width 224 may be less than 90% of maximum width 226, or less than 70% of maximum width 226, or less than 60% of maximum width 226, or less than 50% or less of maximum width 226. It is understood that other suitable dimensions, geometries, and configurations for the ice-making mold 200 may be used without departing from the scope of this invention. Additionally, although only two ice-making molds 200 are shown in fig. 6 and 7, it should be understood that alternative embodiments may include any other suitable number and configuration of ice-making molds 200.

Still referring to fig. 6 and 7, the evaporator assembly 202 can generally include a primary evaporator tube 230 and a thermal enhancement structure 232 positioned within the primary evaporator tube 230. According to one exemplary embodiment, the primary evaporator tube may be a copper tube having a circular cross-section. The diameter of the primary evaporator tube 230 may be between about 0.1 inches and 3 inches, or between about 0.2 inches and 2 inches, or between about 0.3 inches and 1 inch, or between about 0.4 inches and 0.8 inches, or about 0.5 inches. It should be understood, however, that the primary evaporator tube 230 may take any other suitable size, shape, length, and material.

As used herein, "thermal enhancement structure" generally refers to any suitable material, structure, or functional component disposed inside the primary evaporator tube 230 that is intended to increase the refrigerant side surface area within the primary evaporator tube 230. For example, as best shown in fig. 8, the thermal enhancement structure 232 may be a plurality of inner tubes 240 stacked within the primary evaporator tube 230. Generally, these inner tubes 240 may be copper tubes having a diameter smaller than the diameter of the primary evaporator tube 230. The inner tube 240 may be stacked in the main evaporator tube 230 and extend substantially the same length as the main evaporator tube 230.

According to an exemplary embodiment, the thermal enhancement structure 232 may include more than 5 tubes, or more than 10 tubes, or more than 15 tubes, or more than 20 tubes or more. Additionally/or alternatively, the thermal enhancement structure 232 may include less than 50 tubes, or less than 25 tubes, or less than 10 tubes or less. Each inner tube 240 may have a diameter of between about 0.01 inches and 0.5 inches, or between about 0.04 inches and 0.2 inches, or between about 0.06 inches and 0.1 inches, or about 0.08 inches. Additionally, it should be understood that the inner tube 240 may have different sizes, lengths, or cross-sectional shapes, for example, to effectively and completely fill the primary evaporator tube 230.

Alternatively, as shown in fig. 10, the thermal enhancement structure 232 may include a foamed copper structure or a reticulated copper structure 242. Alternatively, the thermal enhancement structure 232 may be a porous thermally conductive material, a honeycomb structure, a lattice structure, or any other suitable thermally conductive material that extends from the inner wall of the primary evaporator tube 230 through the center of the primary evaporator tube 230 to increase the refrigerant side surface area. It is understood that any other suitable thermal enhancement structure 232 may be used without departing from the scope of the present invention.

After the thermal enhancement structure 232 is disposed within the primary evaporator tube 230, the primary evaporator tube 230 can be pressed or otherwise made into a flat or non-circular cross-sectional shape, as generally shown in fig. 6 and 7. As such, the primary evaporator pipe 230 may be disposed in direct contact with the top wall 210 of the ice making mold 200, and may have better thermal contact with the top wall 210. In addition, the larger contact surface area between the top wall 210 and the primary evaporator tube 230 facilitates a simplified hard soldering process to join the primary evaporator tube 230 with the top wall 210. Additionally, pressing the primary evaporator tube 230 into a non-circular cross-section may improve thermal contact between the inner tubes 240, for example, to increase the refrigerant side surface area of the evaporator assembly 200. According to an exemplary embodiment, once formed, the evaporator assembly 202 may be used with the seal cooling system 112. Thus, for example, the compressor 114 may facilitate a flow of refrigerant through the condenser 116, the expansion device 118, and the evaporator assembly 202 as described above.

Since the construction of the ice maker 100 and the evaporator assembly 202 have been described in accordance with exemplary embodiments, an exemplary method 300 of making the evaporator assembly will be described below. Although the following discussion relates to an exemplary method 300 of making the evaporator assembly 202, one skilled in the art will appreciate that the exemplary method 300 is applicable to the operation and method of making a variety of other evaporator configurations.

Referring now to FIG. 10, method 300 includes step 310, where a thermal enhancement structure is placed within a primary evaporator tube. In this regard, as described above, the thermal enhancement structure 230 may be a copper inner tube 240 or a foamed copper structure 242. For example, 15 inner tubes having an outer diameter of 0.08 inches may be provided within the primary evaporator tube 230, which may be a 0.5 inch diameter copper tube.

After the thermal enhancement structure is in place, step 320 is performed in which the primary evaporator tube is pressed into a non-circular shape to increase the thermal contact between the thermal enhancement structure and the primary evaporator tube. In this regard, for example, the primary evaporator tube 230 can be squeezed or compressed to deform the primary evaporator tube 230 and improve the thermal contact between each of the inner tubes 240 and the primary evaporator tube 230, as shown, for example, by the dashed lines in fig. 8 and 9. The primary evaporator tube 230 can then be installed in a sealed refrigeration system, such as in the sealed cooling system 112 like the evaporator 120.

Step 330 includes attaching the primary evaporator tube to an ice-making mold that defines a mold cavity. In this regard, for example, the deformed primary evaporator tube 230 may be soldered, brazed, or otherwise attached to the top wall 210 of the ice-making mold 200. As such, when the hermetic cooling system 112 circulates the refrigerant, the main evaporator pipe 230 absorbs heat energy from the ice making mold 200 and transfers it to the refrigerant. The thermal enhancement structure 232 enables more efficient transfer of thermal energy from the ice-making mold 200 to the refrigerant.

For purposes of illustration and discussion, FIG. 10 depicts steps performed in a particular order. Using the teachings provided herein, one of ordinary skill in the related art will recognize that the steps of any of the methods provided herein can be modified, rearranged, expanded, omitted, or altered in various ways without departing from the scope of the invention. Further, while aspects of the method 300 are explained using the ice maker 100 and the evaporator assembly 202 as examples, it should be understood that the methods may be applied to the operation of any evaporator assembly or ice maker having any other suitable configuration.

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.

Claims

An ice making assembly, comprising:

an ice-making mold defining a mold cavity;

an evaporator assembly thermally coupled to the ice-making mold, the evaporator assembly comprising:

a main evaporator pipe directly contacting the ice-making mold; and

a thermal enhancement structure located within the primary evaporator tube.
An icemaker assembly according to claim 1 wherein said ice-making mold comprises:

a top wall; and

a plurality of side walls depending from the top wall and extending downwardly therefrom.
An icemaker assembly according to claim 2 wherein said evaporator assembly is in direct contact with a top wall of an ice-making mold.
An icemaker assembly according to claim 2 wherein said top wall and said plurality of side walls are made from a sheet of copper plate and have the same thickness.
An icemaker assembly according to claim 2 wherein said top wall defines a top width and said mold cavity defines a maximum width, said top width being greater than 50% of said maximum width.
An icemaker assembly according to claim 2 wherein each of said plurality of side walls is spaced apart by a gap to flex relative to one another.
An icemaker assembly according to claim 2 wherein said plurality of side walls comprises eight side walls forming a mold cavity having an octagonal cross-section.
An icemaker assembly according to claim 1 wherein said icemaker assembly includes a plurality of ice-making molds, said evaporator assembly being thermally coupled to each of the plurality of ice-making molds.
An icemaker assembly according to claim 1 wherein said thermal enhancement structure comprises a foamy copper structure.
An icemaker assembly according to claim 1 wherein said thermal enhancement structure comprises a plurality of internal tubes.
An icemaker assembly according to claim 1 wherein said primary evaporator tube is formed with a non-circular cross-section.
An icemaker assembly according to claim 10 wherein said plurality of inner tubes comprises more than 10 tubes.
An icemaker assembly according to claim 10 wherein said plurality of internal tubes comprises 15 tubes.
An icemaker assembly according to claim 1 wherein said primary evaporator tube is a half inch copper tube.
The ice making assembly of claim 1, further comprising:

a refrigeration circuit including a condenser and an expansion device in series fluid communication with each other and with the evaporator assembly; and

a compressor operatively connected to the refrigeration circuit and configured to circulate a flow of refrigerant in the refrigerant circuit.
A method of making an ice-making assembly comprising:

disposing a thermal enhancement structure within the primary evaporator tube;

pressing the primary evaporator tube into a non-circular shape to increase thermal contact between a thermal enhancement structure and the primary evaporator tube;

a primary evaporator tube is attached to an ice-making mold defining a mold cavity.
The method of claim 16, wherein the primary evaporator tubes are soldered or brazed to a top wall of an ice-making mold.
The method of claim 16, wherein the ice-making mold comprises:

a top wall; and

a plurality of side walls depending from the top wall and extending downwardly therefrom.
The method of claim 18, wherein each of the plurality of sidewalls is spaced apart by a gap to flex relative to each other.
The method of claim 16, wherein the thermal enhancement structure comprises a foamed copper structure or a plurality of internal tubes.