Refrigerator appliance having a sealed system with supplemental heat features and methods of operation
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Solution Overview
Problem
Existing refrigerator appliances with multiple evaporators face inefficiencies and refrigerant migration issues, particularly when attempting to maintain separate temperature settings for freezer and fresh food chambers, leading to increased energy consumption and undesirable refrigerant flow.
Innovation Solution
A refrigerator appliance with a sealed refrigerant system featuring a controller that directs refrigerant flow and supplemental heat to prevent refrigerant backflow, utilizing a multi-path valve and bypass line to manage refrigerant flow between evaporators, and an electric heating element to maintain desired temperatures without counterflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separate fresh food evaporator is provided to maintain fresh food chamber temperature, then temperature control of fresh food chamber is improved, but refrigerant may migrate upstream from fresh food evaporator to freezer chamber
Solution Approach 1:
A bypass line with a bypass valve is introduced as an intermediary pathway. When the fresh food evaporator becomes excessively cold, the bypass valve opens to allow warmer refrigerant to flow through the bypass line, preventing upstream migration into the freezer chamber while maintaining fresh food chamber temperature control.
Solution Approach 2:
The system dynamically changes refrigerant flow parameters by switching between two pathways: the normal path through the fresh food evaporator and the bypass path. The bypass valve adjusts refrigerant flow distribution based on temperature conditions, preventing harmful refrigerant migration while maintaining effective temperature control.
2Temperature
If fresh food evaporator is chilled to maintain selected fresh food temperature, then fresh food chamber cooling is improved, but energy consumption increases due to excessive chilling
Solution Approach 1:
The system allows the fresh food evaporator to be chilled beyond what is strictly necessary (excessive action) when freezer cooling is needed, but uses the bypass valve to prevent continuous excessive chilling. The bypass opens when the evaporator becomes too cold, allowing the system to achieve freezer cooling goals without wasteful continuous operation of the fresh food evaporator.
Solution Approach 2:
The bypass valve operates periodically based on temperature conditions. When the fresh food evaporator reaches a sufficiently cold temperature, the bypass opens to allow warmer refrigerant through, preventing continuous excessive cooling. This periodic modulation reduces energy consumption while maintaining adequate fresh food chamber temperature control.
3Ease of operation
If multiple evaporators are used to separately cool multiple chambers, then control over individual chambers is improved, but refrigerant flow management becomes complex
Solution Approach 1:
The bypass line and bypass valve serve multiple functions: they prevent refrigerant upstream migration, modulate refrigerant flow to the fresh food evaporator, and provide an alternative pathway for refrigerant circulation. This multi-functionality simplifies the overall system by using a single component to address multiple control challenges.
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
Enhances efficiency by up to 5% compared to existing systems, preventing refrigerant migration and maintaining optimal temperature settings in both chambers with reduced energy consumption.
Implementation Method 1
an electric heating element to maintain desired temperatures without counterflow
Implementation Method 2
a condenser disposed along the refrigerant loop downstream from the compressor
Implementation Method 3
a freezer evaporator mounted at the freezer chamber in fluid communication between the condenser and the compressor, and a fresh food evaporator mounted at the fresh food chamber
Data Source
AI summary
A refrigerator appliance may include a cabinet, a fresh food door, a freezer doo, a sealed refrigerant system, and a controller. The sealed refrigerant system may include a refrigerant loop, a compressor disposed along the refrigerant loop, a condenser disposed along the refrigerant loop downstream from the compressor, a freezer evaporator mounted at the freezer chamber in fluid communication between the condenser and the compressor, and a fresh food evaporator mounted at the fresh food chamber between the condenser and the compressor. The controller may be in operable communication with the sealed refrigerant system. The controller may be configured to direct an operation routine. The operation routine may include halting refrigerant flow through the freezer evaporator, directing a supplemental heat to the refrigerant loop between the condenser and the compressor, and directing refrigerant through the fresh food evaporator for a fresh food cooling cycle while directing supplemental heat.