REFRIGERATOR APPLIANCE AND CORRESPONDING CONTROL SYSTEM

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

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

TECHNICAL FIELD

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

BACKGROUND

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

SUMMARY

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

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

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

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevated front view of a French-Door Bottom Mount type refrigerator appliance;

FIG. 2 is an elevated front view of a French-Door Bottom Mount type refrigerator with the refrigerator compartment doors open;

FIG. 3 is a diagram illustrating a refrigeration loop that is configured to cool the interior space (e.g., refrigerator compartment or freezer compartment) of the refrigerator and a control system configured to control the climate within the interior space of the refrigerator; and

FIG. 4 is a method for controlling the cooling system for a refrigerated space or compartment.

DETAILED DESCRIPTION

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

Referring to FIGS. 1 and 2, generally a refrigerator 10 of the French-Door Bottom Mount type is illustrated. However, it should be understood that this disclosure could apply to any type of refrigerator, such as a side-by-side, two-door bottom mount, or a top-mount type. As shown in FIGS. 1 and 2, the refrigerator 10 may have a first internal storage chamber or fresh food compartment 12 configured to refrigerate and not freeze consumables within the fresh food compartment 12, and a second internal storage chamber or a freezer compartment 14 configured to freeze consumables within the freezer compartment 14 during normal use. The refrigerator 10 includes panels or walls 13 that form a housing or cabinet 11. The walls 13, housing, and/or cabinet 11 define the fresh food compartment 12 and the freezer compartment 14. The walls 13 may more specifically form an internal liner of the refrigerator 10. The walls 13 may include a rear or back wall, a top wall, a bottom wall, and two side walls.

One or more shelves 15 may be secured to the walls 13 within the fresh food compartment 12. One or more drawers 17 may be slidably secured to the shelves 15 or the walls within the fresh food compartment 12. More specifically, the drawers 17 may be slidably secured to the shelves 15 or the walls within the fresh food compartment 12 via tracks or rails. One or more of the drawers 17 may be either a pantry drawer 19 or a crisper drawer 21. Crisper drawer 21 may more specifically be drawers defining a storage space that is kept at a desired humidity that may be different from the remainder of the fresh food compartment 12, but that is optimal for maintaining freshness of fruits and vegetables.

The refrigerator 10 may have one or more doors 16, 18 that provide selective access to the interior volume of the refrigerator 10 where consumables may be stored. As shown, the fresh food compartment doors are designated 16, and the freezer door is designated 18. It may also be shown that the fresh food compartment 12 may only have one door 16. The doors 16 may be rotatably secured to the walls 13 by one or more hinges.

It is generally known that the freezer compartment 14 is typically kept at a temperature below the freezing point of water, and the fresh food compartment 12 is typically kept at a temperature above the freezing point of water and generally below a temperature of from about 35° F. to about 50° F., more typically below about 38° F.

The doors 16 may each include an exterior panel 20 and an interior panel 22 that is disposed on an internal side of the respective exterior panel 20 of each door 16. The interior panels 22 may be configured to face the fresh food 12 compartment when the doors 16 are in closed positions (See FIG. 1). The interior panel 22 may more specifically be a door liner. An insulating material, such as an insulating foam, may be disposed between the exterior panel 20 and interior panel 22 of each door 16 in order reduce the heat transfer from the ambient surroundings and increase the efficiency of the refrigerator.

The doors 16 may also include storage bins 24 that are able to hold food items or containers. The storage bins 24 may be secured to the interior panels 22 of each door 16. Alternatively, the storage bins 24 may integrally formed within or defined by the interior panels 22 of each door 16. In yet another alternative, a portion of the storage bins 24 may be secured to the interior panels 22 of each door 16, while another portion of the storage bins 24 may be integrally formed within or defined by the interior panels 22 of each door 16. The storage bins 24 may include shelves (e.g., a lower surface upon, which a food item or container may rest upon) that extend from back and/or side surfaces of the interior panels 22 of each door 16.

Referring to FIG. 3, the refrigerator 10 includes refrigeration system. The refrigeration system includes a refrigeration loop or circuit 36 that is configured to cool the air the within the fresh food compartment 12, the freezer compartment 14, and/or other designated refrigerated space. The refrigeration loop or circuit 36 may also be referred to as a refrigerant loop or circuit. The refrigeration loop or circuit 36 includes at least a compressor 38, an evaporator 40 that cools air being delivered to the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space, a condenser 42 that rejects heat to ambient surroundings 53, and an expansion device, such as a thermal expansion valve 44. The refrigeration loop or circuit 36 may also include an accumulator 46. The accumulator 46 may be located between the evaporator 40 and the compressor 38. The accumulator 46 prevents liquid refrigerant that did not evaporate in the evaporator 40 from flowing into the compressor 38. The refrigeration loop or circuit 36 includes lines or tubes 48 that are configured to transport the refrigerant between the evaporator 40, compressor 38, condenser 42, thermal expansion valve 44, and accumulator 46. The evaporator 40 and condenser 42 are each heat exchangers (e.g., tube and fin heat exchangers).

Fans 50 may be utilized to direct air across the evaporator 40 and the condenser 42 to facilitate exchanging heat. The air may be directed by the fans 50 through flow paths, channels, or conduits 51. A first set of the conduits 51 may direct the air across the evaporator 40, where the air is cooled during the flow cycles of the refrigerant through the refrigeration loop or circuit 36. The cooled air is then directed into the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space. A second set of the conduits 51 may direct the air across the condenser 42, where the air is heated during the flow cycles of the refrigerant through the refrigeration loop or circuit 36. The heated air is then directed to the ambient surroundings 53 to reject the heat regenerated during the flow cycles of the refrigerant through the refrigeration loop or circuit 36.

One or more dampers 55 may be disposed within at least one of the conduits 51 to either increase or decrease air flow across the evaporator 40. Opening the damper 55, which may be disposed between the evaporator 40 and a refrigerated compartment (e.g., the fresh food compartment 12, the freezer compartment 14, or other refrigerated space) increases cooling within such a refrigerated compartment, while closing the damper decreases cooling within the refrigerated compartment. The compressor 38, the fans 50, and the dampers 55 may be connected to a controller 52.

Sensors 54 that measure the air temperature and/or humidity within the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space may be in communication with the controller 52, and may be configured to generate and deliver temperature and/or humidity data (e.g., the air temperature and/or humidity within the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space) to the controller 52. Alternatively, or in addition to the sensors 54, one or more infrared cameras 56 may be disposed within the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space, where the one or more infrared cameras 56 are configured to measure the temperature of objects (e.g., food items) disposed within the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space.

The one or more infrared cameras 56 are configured to generate and deliver temperature data (e.g., the air temperature and/or humidity within the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space or the temperature of one or more items disposed within the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space) to the controller 52.

The controller 52 may be configured to activate and/or operate the refrigeration system (or more specifically the controller 52 may be configured to activate and/or operate specific components of the refrigeration system such as the compressor 38, fans 50, open dampers 55, etc.) in response to the air temperature and/or humidity (e.g., determined via the sensors 54) within the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space being greater than or exceeding a first temperature threshold or setpoint, or in response to a temperature of one or more objects (e.g., determined via the one or more infrared cameras 56) disposed within the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space being greater than or exceeding the first temperature threshold or setpoint.

The controller 52 may also be configured to deactivate or shut down the refrigeration system (or more specifically the controller 52 may be configured to deactivate or shut down specific components of the refrigeration system such as compressor 38, fans 50, close dampers 55, etc.) in response to the air temperature and/or humidity (e.g., determined via the sensors 54) within the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space being less than or falling below a second temperature threshold or setpoint, or in response to a temperature of one or more objects (e.g., determined via the one or more infrared cameras 56) disposed within the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space being less than or falling below the second temperature threshold or setpoint.

The system may include a hysteresis such that the acceptable temperature of the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space (or the temperature of one or more items disposed within the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space) corresponds to a desired range between the first and second temperature thresholds. For example, the first temperature threshold may be greater than the second temperature threshold such that the controller 52 initiates cooling via operating the compressor 38, fans 50, dampers 55, etc. once the temperature of fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space (or the temperature of one or more items disposed within the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space) reaches or exceeds first temperature threshold but does not cease operating the operating the compressor 38, fans 50, dampers 55, etc. until the temperature of fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space (or the temperature of one or more items disposed within the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space) drops to or below the second threshold. The compressor 38, fans 50, dampers 55, etc. may then remain shut down until the temperature of fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space (or the temperature of one or more items disposed within the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space) once again reaches or exceeds the first threshold.

The controller 52 may be part of a larger control system and may be controlled by various other controllers throughout the refrigerator 10, and one or more other controllers can collectively be referred to as a “controller” that controls various functions of the refrigerator 10 in response to inputs or signals to control functions of the refrigerator 10. The controller 52 may include a microprocessor or central processing unit (CPU) in communication with various types of computer readable storage devices or media (e.g., a non-transitory computer readable medium having instructions stored thereon). Computer readable storage devices or media may include volatile and nonvolatile storage in read-only memory (ROM), random-access memory (RAM), and keep-alive memory (KAM), for example. KAM is a persistent or non-volatile memory that may be used to store various operating variables while the CPU is powered down. Computer-readable storage devices or media may be implemented using any of a number of known memory devices such as PROMs (programmable read-only memory), EPROMS (electrically PROM), EEPROMs (electrically erasable PROM), flash memory, or any other electric, magnetic, optical, or combination memory devices capable of storing data, some of which represent executable instructions, used by the controller 52 in controlling the refrigerator 10.

Control logic or functions performed by the controller 52 may be represented by flow charts or similar diagrams in one or more figures. These figures provide representative control strategies and/or logic that may be implemented using one or more processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. As such, various steps or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Although not always explicitly illustrated, one of ordinary skill in the art will recognize that one or more of the illustrated steps or functions may be repeatedly performed depending upon the particular processing strategy being used. Similarly, the order of processing is not necessarily required to achieve the features and advantages described herein, but is provided for case of illustration and description. The control logic may be implemented primarily in software executed by a microprocessor-based controller, such as controller 52. Of course, the control logic may be implemented in software, hardware, or a combination of software and hardware in one or more controllers depending upon the particular application. When implemented in software, the control logic may be provided in one or more computer-readable storage devices or media having stored data representing code or instructions executed by a computer to control the refrigerator 10 or its subsystems. The computer-readable storage devices or media may include one or more of a number of known physical devices which utilize electric, magnetic, and/or optical storage to keep executable instructions and associated calibration information, operating variables, and the like.

Current solutions for controlling the temperature within a refrigerated space (e.g., a refrigerator cavity such as the fresh food compartment 12 or the freezer compartment 14) rely on monitoring air temperature of the compartment or supply air channel. This may not provide an estimate of the temperature of specific food items disposed within such a refrigerated space. Different food items in the refrigerator may have different densities and characteristics. Therefore, the rate of cooling of such different food items may also differ. Monitoring air temperature within a refrigerated space may not include monitoring heat losses. Such a system will continue to cool the refrigerated space until the air within refrigerated space cools down to a set point or threshold, which could lead to inefficiencies.

The proposed solution described herein, may monitor the temperature of objects within the refrigerated space (e.g., the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space) via the one or more infrared cameras 56. Furthermore, the one or more infrared cameras 56 may generate a temperate or heat map of the items within the refrigerated space, which may illustrate the temperatures the specific items disposed within the refrigerated space. The one or more infrared cameras 56 may communicate to the controller 52 if the specific items disposed within the refrigerated space are over-cooling or freezing. The controller 52 may then control the compressor 38, the fans 50, the dampers 55, etc. to adjust the amount of cooling being delivered to the refrigerated space to prevent the specific items disposed within the refrigerated space from over-cooling or freezing, which operates to prevent wastage of food and waste of energy spent in cooling the refrigerated space. The controller 52 may send a notification to a user interface 58 of the refrigerator that includes a display to notify a user that items in the refrigerated space are over-cooling or freezing. The controller 52 may also or alternatively send a notification to an external device or mobile device 60 (e.g., a smartphone, laptop, personal assistant device, tablet, etc.) via wireless communication (e.g., a mobile network, Bluetooth®, Wi-Fi, etc.) to notify a user that items in the refrigerated space are over-cooling or freezing. The controller 52 and external or wireless device 60 may each include or may each be connected to transmitters, receivers, transceivers, antennas 62, etc. to facilitate wireless communication.

The one or more infrared cameras 56 may be used in a special compartment or drawer (e.g., one of the drawers 17, such as pantry drawer 19 or crisper drawer 21) with the refrigerator 10 where the temperature of an object or item disposed within the special compartment may be monitored, and cooling may be accomplished relatively quickly. Based on the set point or desired temperature of the item or object, the system will continue to operate the compressor 38, until the desired temperature is of the object or item is obtained as observed by the one or more infrared cameras 56. Since air temperature and actual temperature of the item may be different, current systems that utilize air temperature within a refrigerated space to control cooling in the refrigerated space may guess as to whether or not items placed within the refrigerated space are actually cooled down to desired temperature. Using infrared cameras, on the other hand, allows items or objects disposed within a refrigerated space to be actively cooled until these items or objects reach desired temperatures. This may be particularly advantageous for items that require to be stored at specific temperatures (e.g., medicines).

The one or more infrared cameras 56 may also be utilized to map the temperature within the refrigerated space (e.g., the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space) against or relative to the desired set point or desired temperature. This will prevent cooling losses that can occur due to poor seals. This data may also be used for providing pro-active service to the customers. Such a temperature or heat map could be displayed at the user interface 58 or on a mobile device 60.

It should be understood that the refrigeration loop or circuit 36 and corresponding system/components illustrated in FIG. 3 are for illustrative purposes only and that the system in FIG. 3 may be reconfigured. For example, the refrigerator 10 may include two refrigeration loops or circuits 36, where one of the refrigeration loops or circuits 36 is configured to cool air entering the fresh food compartment 12 while the second of the refrigeration loops or circuits 36 is configured to cool air entering the freezer compartment 14. As another example, the refrigeration loop or circuit 36 may include two evaporators, wherein one is configured to cool air entering the fresh food compartment 12 while the other is configured to cool air entering the freezer compartment 14.

Referring to FIG. 4, a method 100 for controlling the cooling the system (e.g., the refrigeration loop or circuit 36 and the corresponding system/components illustrated in FIG. 3) for a refrigerated space or compartment (e.g., a refrigerator cavity such as the fresh food compartment 12, the freezer compartment 14, special compartment, or drawer (e.g., one of the drawers 17, such as pantry drawer 19 or crisper drawer 21) of a refrigerator appliance) is illustrated. The method 100 beings at block 102 where the temperature of one or more items disposed within the refrigerated space is monitored (e.g., via the one or more infrared cameras 56). Next, the method 100 moves on to block 104 where the cooling system of the refrigerated space is controlled to drive the temperature of the one or more items disposed within the refrigerated space toward desired set points or desired temperatures. More specifically, at block 104, the controller 52 may control the compressor 38, the fans 50, the dampers 55, etc. to adjust the cooling being delivered to the refrigerated space to drive the items disposed within the refrigerated space toward desired temperatures and to prevent the items disposed within the refrigerated space from over-cooling or freezing.

Moving on to block 106, if the temperatures of the items within the refrigerated space are outside of a threshold from the desired set points (e.g., if the items have temperatures that are lower than the desired set points by at least a threshold, if the items are freezing, or if the items have temperatures that are higher than the desired set points by at least a threshold after a predetermined time period in spite of cooling the refrigerated space), the method 100 may notify the user that the temperatures of the items are not reaching the desired set point temperatures. Next, the method moves on to block 108 where the cooling system (or more specifically the one or more infrared cameras 56 and the controller 52) is utilized to generate a temperature or heat map of the refrigerated space, including the items within the refrigerated space. The temperature or heat map is then communicated to the user (e.g., via the user interface 58 or wirelessly to the mobile device 60) at block 110. The temperature or heat map may be indicative of whether or not items are being sufficiently cooled within the refrigerated space or if the refrigerated space is being sufficiently sealed. In the event there is insufficient cooling or sealing of the refrigerated space, the communication of the temperature or heat map may include a special notification, alert, or warning of the insufficiency or insufficiencies. Furthermore, communication may occur at block 110 to a repair or service center where appropriate maintenance may be scheduled or required replacement parts (e.g., new seals around the refrigerator door) may be ordered.

The steps at blocks 102, 104, and 106 may be separated from blocks 108 and 110 such that the blocks 102, 104, and 106 form a first method and blocks 108 and 110 form a second method. Furthermore, it should be understood that the flowchart in FIG. 4 is for illustrative purposes only and that the method 100 should not be construed as limited to the flowchart in FIG. 4. Some of the steps of the method 100 may be rearranged while others may be omitted entirely.

The solution described herein prevents over cooling or freezing of produce. Controlling the temperature of the air in the refrigerated space may not equally cool all the items. Some items may cool sooner than others or some items could semi-freeze. The one or more infrared cameras 56 monitor the temperature of the items in the refrigerated space and, in conjunction with the controller 52, facilitate adjusting the amount of cooling to the refrigerated space and/or notifying the consumer or user in response to the temperature of the items within the refrigerated space decreasing to lower than optimum temperatures.

The solution described herein also facilitates reliable and fast cooling within a special compartment or drawer (e.g., one of the drawers 17, such as pantry drawer 19 or crisper drawer 21). The consumer or user may set a target temperature for cooling an item within such a special compartment or cooling drawer to cool the item as soon as possible or within a desired timeframe that may be shorter than a standard timeframe. The infrared camera 56 may constantly monitor the temperature of the target item while the system may use the temperature reading of the item (as opposed to the air temperature) and maintain operation of the compressor 38 until the item has reached the setpoint or desired temperature. The consumer or user may be notified via the user interface 58 or on a mobile device 60 when the item has reached the desired temperature.

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

The solution described herein also may be utilized to check for temperature losses in the refrigerator cabinet 11 in the form of a temperature or heat map. Such a temperature or heat map may be a temperature or heat map of the inside of the refrigerator cabinet 11 within a refrigerated space (e.g., the fresh food compartment 12, the freezer compartment 14, and/or other refrigerated space (e.g., one of the drawers 17, such as pantry drawer 19 or crisper drawer 21)). This will facilitate identifying leaks occurring due to poor seals or poor alignment of the refrigerator door. The refrigerator controller 52 may automatically contact a repair or service center via transmitters, receivers, transceivers, antennas 62, etc. when a leakage issue is detected, order replacement parts, and/or schedule appropriate service.

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

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