FAN WITH INTEGRATED PLENUM

Abstract

A condenser fan assembly for a refrigerator appliance is provided including a plurality of blades, an electric motor in mechanical communication with the plurality of blades, and a fan housing. The fan housing is configured to separate the utility compartment defined by a cabinet of the refrigerator appliance into two zones. The fan housing includes a plenum, one or more support arms, and a backplate. The electric motor is attached the backplate, and the plenum, the one or more support arms, and the backplate are all formed integrally to increase an efficiency of the condenser fan assembly.

Description

FIELD OF THE INVENTION

The present subject matter relates generally to a refrigerator appliance, or more particularly, to a condenser fan assembly for a refrigerator appliance.

BACKGROUND OF THE INVENTION

Consumer refrigerator appliances generally utilize a relatively simple sealed system that includes a compressor, a condenser, an expansion device, and an evaporator connected in series, in parallel, or in a hybrid configuration. The system is charged with a refrigerant, such as R-134a. During operation, the refrigerant is pressurized using the compressor, raising the temperature of the refrigerant. The refrigerant is then flowed to the condenser, wherein heat from the refrigerant is exchanged, lowering the temperature of the refrigerant. From the condenser, the refrigerant enters the expansion device and, upon exiting the expansion device, the refrigerant enters the evaporator to further reduce the temperature and pressure of the refrigerant. Additionally, the refrigerant may change phase from a liquid to a gas in the evaporator. Heat from a chilled chamber of the refrigerator appliance (e.g., a freezer chamber or a fresh food chamber) is transferred to the refrigerant within the evaporator, reducing a temperature of the chilled chamber of the refrigerator appliance.

One or more of the components of the sealed system may be positioned in a utility compartment of the refrigerator appliance, with a back panel provided to cover the utility compartment. A condenser fan assembly can be positioned within the utility compartment adjacent to the condenser to provide an airflow over the condenser and increase an amount of heat transfer from the condenser to, e.g., ambient surroundings of the refrigerator appliance. Moreover, the condenser fan assembly can be positioned within the utility compartment between an inlet vent and an exhaust vent on the back panel to allow such an airflow over the condenser.

The condenser fan assembly includes various components to generate the airflow over the condenser. However, it can be difficult to create a durable and effective seal between the various components. For example, the seal can break down over continued use, allowing for airflow to circulate from the downstream side of the utility compartment back to the upstream side of the utility compartment between the various components of the condenser fan assembly, reducing the fan assembly's efficiency. Additionally, such a configuration can allow for an undesirable rattling noise between the components.

Therefore, a condenser fan assembly that allows for an effective and durable seal between the various components would be beneficial. More particularly, a condenser fan assembly that can reduce a risk of air circulation from the downstream side to the upstream side of the plenum and reduce a risk of undesirable rattling noises of the components would be particularly useful.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention are set forth below in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In one exemplary embodiment of the present disclosure, a condenser fan assembly for a refrigerator appliance is provided including a plurality of blades, an electric motor in mechanical communication with the plurality of blades, and a fan housing configured to separate a utility compartment within the refrigerator into two zones. The fan housing includes a plenum, one or more support arms, and a backplate. The electric motor is attached to the backplate and the one or more support arms extend from the backplate towards the plenum. Additionally, the plenum, the backplate, and the one or more support arms are formed integrally.

In another exemplary embodiment of the present disclosure, a refrigerator appliance is provided including a cabinet defining at least one refrigerated compartment and a utility compartment. The refrigerator appliance also includes a sealed system configured to provide cooled air to the at least one refrigerated compartment. The sealed system includes a condenser positioned in the utility compartment. The refrigerator appliance additionally includes an electric motor positioned in the utility compartment adjacent to the condenser and in mechanical communication with a plurality of blades, and a condenser fan housing. The condenser fan housing is configured to separate the utility compartment into a high pressure zone and a low pressure zone. The condenser fan housing includes a plenum, one or more support arms, and a backplate. The electric motor is attached to the backplate and the one or more support arms extend from the backplate towards the plenum, wherein the plenum, the backplate, and the one or more support arms are formed integrally.

These and other features, aspects and advantages of the present disclosure 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 disclosure and, together with the description, serve to explain the principles of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof to one skilled in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:

FIG. 1 provides a front view of a refrigerator appliance according to an exemplary embodiment of the present subject matter.

FIG. 2 provides a rear view of a bottom portion of the exemplary refrigerator appliance of FIG. 1, with a cover panel removed.

FIG. 3 provides a rear view of the bottom portion of the exemplary refrigerator appliance of FIG. 1, including the cover panel.

FIG. 4 provides a downstream perspective view of a condenser fan assembly according to an exemplary embodiment of the present subject matter.

FIG. 5 provides a downstream plan view of the exemplary condenser fan assembly of FIG. 4.

FIG. 6 provides an upstream perspective view of the exemplary condenser fan assembly of FIG. 4.

FIG. 7 provides an upstream plan view of the exemplary condenser fan assembly of FIG. 4.

DETAILED DESCRIPTION OF THE INVENTION

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. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

FIG. 1 depicts a refrigerator appliance 10 according to an exemplary embodiment of the present subject matter. The refrigerator appliance depicted 10 is an upright, vertically oriented refrigerator having a cabinet or casing 12 that defines at least one refrigerated compartment. In particular, refrigerator appliance 10 includes an upper fresh-food compartment 14 having doors 16 and a lower freezer compartment 18 having upper drawer 20 and lower drawer 22. The drawers 20, 22 are “pull-out” drawers in that they can be manually moved into and out of the freezer compartment 18 on suitable slide mechanisms.

Refrigerator appliance 10 depicted defines a vertical direction V, a lateral direction L, and a transverse direction (not shown). The vertical direction V, lateral direction L, and transverse direction are mutually perpendicular and form an orthogonal direction system. Additionally, refrigerator appliance 10 extends between a top portion 24 and a bottom portion 26 generally along the vertical direction V, between a first side portion 28 and a second side portion 30 generally along the lateral direction L, and between a front side 32 and a rear side 34 (see FIG. 2) generally along the transverse direction.

It should be appreciated, however, that the refrigerator appliance 10 depicted in FIG. 1 is provided by way of example only and that the term “refrigerator appliance” is used in a generic sense herein to encompass any manner of refrigeration appliance, such as a freezer, refrigerator/freezer combination, and any style or model of conventional refrigerator. Thus, it is within the scope of the present subject matter for other configurations of the refrigerator appliance 10 to be used as well. For example, refrigerator appliance 10 may be provided with any suitable configuration of, e.g., fresh food compartment 14 and/or freezer compartment 20, including any suitable hinged or pull-out doors. Additionally, although refrigerator appliance 10 is depicted as a vertically oriented refrigerator appliance, in other embodiments, the refrigerant appliance 10 may, e.g., be a horizontally oriented refrigerator appliance with a door positioned at e.g. a top side of the refrigerator appliance.

Referring now to FIG. 2, a rear view of the bottom portion 26 of the exemplary refrigerator appliance 10 of FIG. 1 is provided. As shown, the cabinet 12 of the refrigerant appliance 10 further defines a utility compartment 36, which for the embodiment depicted, is positioned at the rear side 34 of the refrigerator appliance 10 towards the bottom portion 26 of the refrigerator appliance 10. The utility compartment 36 includes one or more components of a sealed system 38 of refrigerator appliance 10.

The sealed system 38 provides cooled air to the at least one refrigerated compartments, e.g., the fresh food compartment 14 and/or the freezer compartment 18 of the refrigerator appliance 10. The sealed system 38 generally includes a compressor 40, a condenser 42, an expansion device (not shown), and an evaporator (not shown) connected in series, connected in parallel, or in a hybrid connection configuration by one or more pipes or conduits 44. For example, a refrigerant may be compressed by the compressor 40 to increase a temperature and pressure of the refrigerant such that the refrigerant is in a superheated vapor phase. The pressurized refrigerant may then flow through the condenser 42, wherein at least a portion of the superheated vapor refrigerant is condensed into a liquid phase refrigerant by removing heat from the refrigerant. From the condenser 42, refrigerant may flow through the expansion device whereby the temperature and pressure of the refrigerant is further reduced before traveling to the evaporator. Heat from the one or more refrigerated compartments, e.g., fresh food compartment 14 or freezer compartment 20, may be transferred to the evaporator (and the refrigerant therein), cooling the one or more refrigerated compartments.

For the embodiment depicted, the compressor 40 and the condenser 42 of the sealed system 38 are positioned in the utility compartment 36, with the expansion device and the evaporator positioned elsewhere within the cabinet 12 of the refrigerator appliance 10. The various components are connected using the pipes 44. However, in other exemplary embodiments, one or more of the expansion device and evaporator may also be positioned in the utility compartment 36, or alternatively the compressor 40 may be positioned outside of the utility compartment 36.

As shown, the refrigerator appliance 10 further includes a condenser fan assembly 46 positioned in the utility compartment 36 configured to provide a flow of air over the condenser 42, increasing an efficiency of the sealed system 38. The condenser fan assembly 46 generally includes a plurality of blades 48, an electric motor 50 in mechanical communication with a plurality of blades 48, and a fan housing 52. The fan housing 52 is configured to separate the utility compartment 36 within the refrigerator appliance into two zones. More particularly, the fan housing 52 is configured to separate utility compartment 36 into a high pressure zone 54 and a low pressure zone 56. Accordingly, the fan housing 52 defines a first side 58, which for the embodiment depicted is an upstream side, and a second and opposite side 60, which for the embodiment depicted is a downstream side.

Referring now to FIG. 3, another rear view of the bottom portion 26 of the exemplary refrigerator appliance 10 of FIG. 1 is provided. For the embodiment shown, the refrigerator appliance 10 also includes a back cover panel 62 extending over the utility compartment 36 and attached to the cabinet 12 of the refrigerator appliance 10 using a plurality of screws 64. However, in other embodiments, the back cover panel 62 may instead be attached to the cabinet 12 in any other suitable manner. For example, in other embodiments, the back cover panel 62 may be attached at a first side using one or more hinges, and attached at and opposite side using one or more suitable latches. The back cover panel 62 includes an airflow inlet 66 and an airflow exhaust 68. The airflow inlet 66 may be positioned over the low pressure zone 56 of the utility compartment 36, while the airflow exhaust 68 may be positioned over the high pressure zone 54 of the utility compartment 36. Accordingly, the condenser fan assembly 46 may provide for a flow of air from an ambient surrounding of the refrigerator appliance 10, through the airflow inlet 66 of the back cover panel 62, over the condenser 42 (exchanging heat with the condenser), and out through the airflow exhaust 68 of the back cover panel 62.

It should be appreciated, however, that in other exemplary embodiments, the refrigerator appliance 10 may instead define an airflow inlet 66 and an airflow exhaust 68 in any other suitable location. For example, the cabinet 12 of the refrigerator appliance 10 may define an airflow inlet 66 on the first side 28 of the cabinet and an airflow exhaust 68 on the second side 30 of the cabinet 12.

Reference will now be made to FIGS. 4 and 5. FIG. 4 provides a downstream perspective view of a condenser fan assembly 46 in accordance with an exemplary embodiment of the present disclosure. Additionally, FIG. 5 provides a downstream plan view of the exemplary condenser fan assembly 46 of FIG. 4.

As is shown, the exemplary fan housing 52 of the condenser fan assembly 46 generally includes a plate structure or plenum 70, a fan shroud 72, one or more support arms 74, and a backplate 76. The electric motor 50 is attached to the backplate 76 and the one or more support arms 74 extend from the backplate 76 towards the plenum 70. More particularly, the one or more support arms 74 extend from the backplate 76 to the fan shroud 72, and the fan shroud 72 extends between the support arms 74 and the plenum 70.

The plenum 70, the fan shroud 72, the one or more support arms 74, and the backplate 76 are all formed integrally. As used herein, “formed integrally” refers to one or more components being made from the same material with no seams or gaps therebetween. For example, two components may be formed integrally when they are formed simultaneously using a single mold or die.

Additionally, as stated, the fan housing 52 defines the first side 58 (FIGS. 6 and 7), or upstream side, and the second side 60, or downstream side. The fan shroud 72 extends outwardly along an axial direction A from the plenum 70 on the second side 60 and is cylindrical in shape. Additionally, the fan shroud 72 defines an inner surface 88 and an orifice 90, the inner surface 88 extending along the circumferential direction C around the orifice 90. The electric motor 50 is attached to the backplate 76, and the plurality of blades 48 and electric motor 50 are positioned within the orifice 90 of the fan shroud 72. The fan shroud 72 may assist in directing airflow generated by the plurality of blades 48 and electric motor 50.

Additionally, the plurality of blades 48 each extend between a base 92 and a tip 94. A clearance 96 is defined by the condenser fan assembly 46 between the tips 94 of the plurality of blades 48 and the inner surface 88 of the fan shroud 72. In certain exemplary embodiments, the clearance 96 may be less than or equal to seven (7) millimeters (mm). However, in other exemplary embodiments, the clearance 96 may be less than or equal to three (3) mm, less than or equal to one (1) mm, or less than or equal to eight tenths (0.8) of a mm. Such a configuration is allowable due to the integral formation of the backplate 76, the support arms 74, and the fan shroud 72. More particularly, by forming the backplate 76, the support arms 74, and the fan shroud 72 integrally and attaching the electric motor 50 to the backplate 76, the electric motor 50 may be mounted with relatively high precision within the orifice 90 of the fan shroud 72, and relative to the inner surface 88 of the fan shroud 72. Accordingly, the plurality of blades 48 may define the above clearance 96, increasing an efficiency of the condenser fan assembly 46. More specifically, such a clearance 96 between the tips 24 of the plurality of blades 48 and the inner surface 88 of the fan shroud 72 may reduce an amount of airflow that swirls back upstream around the tips 94 of the plurality of blades 48 (i.e., from the high pressure zone 54 to the low pressure zone 56) during operation of the condenser fan assembly 46.

Referring now to FIGS. 6 and 7, FIG. 6 provides an upstream perspective view of the exemplary condenser fan assembly 46 of FIG. 4 and FIG. 7 provides an upstream plan view of the exemplary condenser fan assembly 46 of FIG. 4. For the embodiment depicted, the first side 58 includes a lip 78 also extending outwardly along the axial direction A from the plenum 70. The exemplary lip 78 is configured to support a condenser assembly 80 (see FIG. 2) of the refrigerator appliance 10. For example, referring back to FIG. 2, the condenser assembly 80 generally includes a cylindrically shaped housing 82 with condenser coils 84 of the condenser 42 positioned therein. The cylindrically shaped housing 82 may correspond in shape with the lip 78 extending from the plenum 70. More particularly, the exemplary lip 78 depicted also defines a generally cylindrical shape having a diameter along a radial direction R slightly larger than a diameter of the cylindrically shaped housing 82 of the condenser assembly 80 along the radial direction R. The housing 82 may therefore be received within the lip 78 of the fan housing 52 condenser fan assembly 46. It should be appreciated, however, that in other exemplary embodiments, the housing 82 and lip 78 may have any other shape. For example, in other exemplary embodiments, the housing 82 and lip 78 may define a squared or rectangular cross-sectional shape.

Additionally, the lip 78 may further include a gasket or foam seal (not shown) extending along the circumferential direction C around an inside surface 86 of the lip 78. Such a configuration may further assist in providing a desired amount of airflow over the condenser coils 84 of the condenser 42. More particularly, such a configuration may ensure airflow from the airflow inlet 66 on the back cover panel 62 flows through the housing 82 of the condenser assembly 80, and thus, over the condenser coils 84 of the condenser 42, to provide the desired amount of heat exchange with the condenser 42. The gasket or foam seal may be a separate component attached to the lip 78, or alternatively may be formed integrally with the lip 78. For example, the gasket may be overmolded with the lip 78 using any suitable material, such as a rubber material.

It should be appreciated, however, that in other exemplary embodiments of the present disclosure, the first side 58 of the fan housing 52 may have any other suitable configuration. For example, in other embodiments, the fan housing 22 may not define the lip 78 for supporting the condenser assembly 80, or alternatively may define any other suitable shape for the lip 78.

Referring now generally to FIGS. 4 through 7, the fan housing 52 further defines an outer perimeter 98. Due to the integral formation of the fan shroud 72 and the plenum 70, the fan housing 52 extends continuously between the fan shroud 72 and the outer perimeter 98 to form an airtight seal between the first side 58 and the second side 60 of the housing 52 from between the fan shroud 72 and the outer perimeter 98 of the housing 52. More particularly, for the embodiment depicted, the orifice 90 of the fan shroud 72 is the only opening in the fan housing 52. The outer perimeter 98 is configured to form a seal within the utility compartment 36 and, for the embodiment depicted, includes a gasket 100 extending around the outer perimeter 98 to assist with such a function. In certain exemplary embodiments the gasket 100 may be a foam gasket, or alternatively may be made of a resilient material, such as a rubber material. Further, the gasket 100 may be a separate component attached to the outer perimeter 98 in any suitable manner, or alternatively may be formed integrally with the outer perimeter 98 of the housing 52. For example, in certain exemplary embodiments, the gasket 100 may be overmolded with the outer perimeter 98 using any suitable material. Accordingly, for the embodiment depicted, the fan housing 52 may allow for a more durable and efficient condenser fan assembly 46, as the risk of air leaking from the high pressure zone 54 to the low pressure zone 56 through the plenum 70, the fan shroud 72, or a seal therebetween is eliminated. Additionally, by forming the plenum 70 integrally with the fan shroud 72, the support arms 74, and the backplate 76, a risk of the fan housing 52 developing one or more unwanted noises during operation of the condenser fan assembly 46 is minimized. More particularly, the risk of a “rattling” between one or more of the plenum 70, the fan shroud 72, the support arms 74, and the backplate 76 due to vibrations of, e.g., the electric motor 50 and the plurality of blades 48, is minimized.

Referring still generally to FIGS. 4 through 7, the outer perimeter 98 defines an indentation 102, which may allow for one or more pipes, such as one or more of the pipes 44 of the sealed system 38 of the refrigerator appliance 10, to extend therethrough. For example, the indentation 102 may allow for one or more of the pipes 44 to extend from the compressor 40 to the condenser 42, and/or from, e.g., the evaporator to the compressor 40. It should be appreciated, however, that in other exemplary embodiments of the present disclosure, the outer perimeter 98 may not define such an indentation 102. Additionally, or alternatively, the fan housing 52 may define one or more openings with suitable gaskets or other sealing mechanisms (not shown) in, e.g., the plenum 70 allowing for one or more pipes 44 of the sealed system 38 to extend therethrough.

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 and 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 language of the claims.

Claims

1. A condenser fan assembly for a refrigerator appliance comprising:

a plurality of blades;

an electric motor in mechanical communication with the plurality of blades; and

a fan housing configured to separate a utility compartment within the refrigerator into two zones, the fan housing comprising a plenum; one or more support arms; and a backplate, the electric motor attached to the backplate and the one or more support arms extending from the backplate towards the plenum, wherein the plenum, the backplate, and the one or more support arms are formed integrally.

2. The condenser fan assembly of claim 1, wherein the fan housing further comprises

a fan shroud defining an orifice, wherein the plurality of blades are positioned in the orifice of the fan shroud, and wherein the fan shroud is formed integrally with the plenum, the backplate, and the one or more support arms.

3. The condenser fan assembly of claim 2, wherein the one or more support arms extend from the backplate to the fan shroud, and wherein the fan shroud extends between the support arms and the plenum.

4. The condenser fan assembly of claim 2, wherein the fan housing defines an upstream side, a downstream side, and an outer perimeter, wherein the fan housing extends continuously between the fan shroud and the outer perimeter to form an air tight seal between the upstream side and the downstream side from between the fan shroud and the outer perimeter.

5. The condenser fan assembly of claim 2, wherein the fan housing defines an upstream side and a downstream side, and wherein the fan shroud extends outwardly along an axial direction from the plenum on the downstream side of the fan housing.

6. The condenser fan assembly of claim 2, wherein the fan housing further comprises a lip extending outwardly along an axial direction from the plenum, the lip configured to support a condenser assembly.

7. The condenser fan assembly of claim 2, wherein the plurality of blades each extend between a base and a tip, wherein the fan shroud defines an inner surface extending circumferentially around the orifice, and wherein the condenser fan assembly defines a clearance between the tips of the plurality of blades and the inner surface that is less than seven millimeters.

8. The condenser fan assembly of claim 1, wherein the fan housing further defines an outer perimeter, the outer perimeter configured to form a seal with the utility compartment.

9. The condenser fan assembly of claim 8, wherein the condenser fan assembly further comprises a gasket extending around the outer perimeter.

10. The condenser fan assembly of claim 9, wherein the gasket is formed integrally with the fan housing.

11. A refrigerator appliance comprising

a cabinet defining at least one refrigerated compartment and a utility compartment;

a sealed system configured to provide cooled air to the at least one refrigerated compartment, the sealed system including a condenser positioned in the utility compartment;

an electric motor positioned in the utility compartment adjacent to the condenser and in mechanical communication with a plurality of blades; and

a condenser fan housing configured to separate the utility compartment into a high pressure zone and a low pressure zone, the condenser fan housing comprising a plenum; one or more support arms; and a backplate, the electric motor attached to the backplate and the one or more support arms extending from the backplate towards the plenum, wherein the plenum, the backplate, and the one or more support arms are formed integrally.

12. The refrigerator appliance of claim 11, wherein the fan housing further comprises

a fan shroud defining an orifice, wherein the plurality of blades are positioned in the orifice of the fan shroud, and wherein the fan shroud is formed integrally with the plenum, the backplate, and the one or more support arms.

13. The refrigerator appliance of claim 12, wherein the one or more support arms extend from the backplate to the fan shroud, and wherein the fan shroud extends between the support arms and the plenum.

14. The refrigerator appliance of claim 12, wherein the fan housing defines an upstream side, a downstream side, and an outer perimeter, wherein the fan housing extends continuously between the fan shroud and the outer perimeter to form an air tight seal between the upstream side and the downstream side from between the fan shroud and the outer perimeter.

15. The refrigerator appliance of claim 12, wherein the fan housing defines an upstream side and a downstream side, and wherein the fan shroud extends outwardly along an axial direction from the plenum on the downstream side of the fan housing.

16. The refrigerator appliance of claim 12, wherein the fan housing further comprises a lip extending outwardly along an axial direction from the plenum, the lip configured to support a condenser assembly.

17. The refrigerator appliance of claim 12, wherein the plurality of blades each extend between a base and a tip, wherein the fan shroud defines an inner surface extending circumferentially around the orifice, and wherein the condenser fan housing defines a clearance between the tips of the plurality of blades and the inner surface that is less than seven millimeters.

18. The refrigerator appliance of claim 11, wherein the fan housing further defines an outer perimeter, the outer perimeter configured to form a seal with the utility compartment.

19. The refrigerator appliance of claim 18, wherein the refrigerator appliance further comprises a gasket extending around the outer perimeter.

20. The refrigerator appliance of claim 19, wherein the gasket is formed integrally with the condenser fan housing.