Refrigerator Door Air Duct Layout for Low-Frost Ice Making
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Solution Overview
Problem
Existing refrigerator designs face issues with cool air loss, increased power consumption, and reduced energy efficiency due to the installation of cool air ducts on the side wall face of the refrigerating chamber, which leads to heat exchange with external air, frost generation, longer duct lengths, and inefficient cool air circulation.
Innovation Solution
A refrigerator design where cool air ducts are positioned within the refrigerating chamber door, allowing direct supply of cool air from the freezing chamber to the refrigerating chamber, with a sealing mechanism to prevent external air infiltration and a damper system to control air flow based on ice level and temperature, optimizing air circulation and reducing the need for a defrosting heater.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cool air ducts are installed on the side wall face of the refrigerating chamber, then cool air can be supplied to the ice making chamber, but the insulation thickness is reduced causing heat exchange with external air and cool air loss
Solution Approach 1:
The cool air ducts are nested within the refrigerating chamber door structure, specifically positioned within the protrusion of the door. This nesting approach allows the ducts to be housed without compromising the external insulation layer, as the door's protrusion provides internal space for duct installation while maintaining the original wall thickness and insulation integrity.
Solution Approach 2:
The duct installation moves from a lateral wall position to a vertical door position, utilizing the third dimension (door depth/protrusion) to accommodate ducts. This dimensional shift allows cool air supply functionality while preserving the insulation thickness of the main chamber walls.
2Loss of energy
If cool air ducts are protruded to the inner side of the inner case to maintain wall thickness, then insulation is preserved, but the valid volume of the refrigerating chamber is reduced
Solution Approach 1:
The refrigerating chamber door is segmented into functional zones: the protrusion area houses the ducts, while the main chamber interior retains full volume. This segmentation isolates the duct installation space to the door structure itself, preventing intrusion into the chamber's valid storage volume.
Solution Approach 2:
Ducts are nested within the door's protrusion structure, utilizing the door's own spatial features rather than encroaching on chamber volume. The protrusion acts as a dedicated duct housing that does not reduce the chamber's usable space.
3Object-affected harmful factors
If heaters are installed between cool air ducts and outer case to prevent frost, then frost generation is reduced, but power consumption increases and cool air temperature rises
Solution Approach 1:
The heaters are extracted from the system by eliminating the thermal bridge between ducts and outer case. The protrusion design isolates ducts from the outer wall, removing the frost risk and eliminating the need for heating elements entirely.
Solution Approach 2:
The design converts the potential harm of cold duct surfaces into a benefit by using the protrusion structure to naturally insulate ducts from external air, eliminating frost formation without active heating.
4Productivity
If cool air ducts are installed on the side wall face, then air flow path is established, but the duct length increases causing more cool air loss and delayed supply
Solution Approach 1:
Instead of extending ducts laterally across the chamber wall, the air flow path is inverted to use the vertical door structure. Cool air flows downward through the door's protrusion, shortening the duct length and reducing thermal loss while maintaining effective air circulation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces cool air loss, minimizes frost generation, decreases power consumption, and enhances energy efficiency by maintaining insulation thickness, prolonging cool air stay in the ice making chamber, and effectively utilizing cool air for both ice making and refrigeration.
Implementation Method 1
at least one evaporator configured to cool air used in regulating operating temperatures in the refrigerating compartment and the freezing compartment
Implementation Method 2
a damper system to control air flow based on ice level and temperature, optimizing air circulation
Implementation Method 3
a sealing mechanism to prevent external air infiltration and maintain insulation thickness
Implementation Method 4
an ice compartment positioned at the refrigerating compartment door and configured to receive cool air from the freezing compartment
Data Source
Figure 1
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Figure 3~4
AI summary
A refrigerator and its operation method are disclosed. Cool air ducts guide cool air from a freezing compartment to an ice compartment that is positioned at a refrigerating compartment door. At least a portion of the cool air ducts are located at a barrier that separates the freezing compartment and the refrigerating compartment.