MULTIPLE EVAPORATOR CONTROL USING PWM VALVE/COMPRESSOR

Abstract

A refrigeration system including a condenser; a (single) linear compressor that is activated and deactivated by a pulse width modulation switching device; a pulse width modulation refrigerant flow switch; at least two evaporators operably connected in parallel with one another with at least one evaporator associated with the refrigerator compartment that operates at a first refrigerant fluid pressure and with at least one other evaporator associated with the freezer compartment that operates at a second refrigerant fluid pressure; and a plurality of refrigerant fluid conduits operably connecting the condenser, the linear compressor and the evaporators into a refrigerant fluid flow circuit and such that the evaporators are capable of running simultaneously at different pressure levels and refrigerant flows from the evaporators, to the pulse width modulation refrigerant flow switch and through the pulse width modulation refrigerant flow switch.

Claims

1. A refrigeration system comprising: a compressor having an outlet and an inlet, a condenser operably coupled to the compressor outlet and configured to receive refrigerant fluid from the compressor; a plurality of evaporators each operating and coupled in parallel to the condenser and each having an inlet pressure side and an outlet pressure side and each receiving refrigerant fluid from the condenser via the inlet pressure side and each outputting refrigerant fluid at different evaporator outlet pressures; refrigerant fluid conduits operably coupling the compressor, the condenser and the plurality of evaporators thereby forming a refrigerant fluid circuit for the transmission of the refrigerant fluid between the compressor, the condenser, and the plurality of evaporators; and a switch valve operably coupled to the outlet pressure side of each of the plurality of evaporators using the refrigerant fluid conduits, wherein the switch valve is configured to switch between any one evaporator of the plurality of evaporators such that the switch valve provides an inlet pressure of refrigerant fluid to the compressor at a pressure between a highest evaporator outlet pressure and a lowest evaporator outlet pressure of the different outlet pressures of the plurality of evaporators.

2. The refrigeration system of claim 1, wherein the compressor is the only compressor operably connected to the refrigeration system.

3. The refrigeration system of claim 1, wherein the condenser is the only condenser operably connected to the refrigeration system.

4. The refrigeration system of claim 3, wherein the compressor is the only compressor operably connected to the refrigeration system.

5. The refrigeration system of claim 1, wherein the switch valve is a pulse width modulation switch valve.

6. The refrigeration system of claim 5, wherein the compressor further comprises a pulse width modulation switch that activates and deactivates the compressor.

7. The refrigeration system of claim 6, wherein the compressor is a linear compressor and the switch valve is configured to switch between refrigerant flow lines at a rate of at least 30 seconds or faster such that the overall system operates in a non-sequential manner.

8. The refrigeration system of claim 7, wherein the switch valve is configured to switch between refrigerant flow lines at a rate of at least about 10 milliseconds or faster and wherein the linear compressor is an oil-less compressor and wherein the system further comprises a plurality of valves, wherein at least one valve is associated with the inlet pressure side of each of the plurality of evaporators and each valve being moveable between an open position and closed position in response to a demand signal, and wherein each valve can be simultaneously or individually opened to supply one or more of the plurality of evaporators with refrigerant fluid such that refrigerant fluid is capable of being supplied to one evaporator at a given time or multiple evaporators of the plurality of evaporators at a given time.

9. The refrigeration system of claim 7, wherein the linear compressor is an orientation flexible compressor.

10. The refrigeration system of claim 2, wherein the compressor is a linear compressor and wherein the switch valve is configured to switch between the refrigerant flow lines at a rate of at least about 30 seconds or faster and cause the refrigerant flow lines to operate sequentially thereby allowing the system to emulate a system with the evaporators in parallel.

11. The refrigeration system of claim 10, wherein the linear compressor is activated and deactivated by a pulse width modulation switching device.

12. The refrigeration system of claim 11, wherein the linear compressor is an orientation flexible and oil-less compressor.

13. The refrigeration system of claim 1, wherein the plurality of evaporators comprises a first evaporator associated with a fresh food compartment, a second evaporator associated with a freezer compartment, and a third evaporator associated with at least one of a powered component or an appliance drawer compartment.

14. The refrigeration system of claim 13, wherein the third evaporator is associated with a powered component and the powered component is an ice maker.

15. The refrigeration system of claim 1, wherein the plurality of evaporators consists of a first evaporator and a second evaporator configured in parallel in the system and the compressor has a single inlet that receives refrigerant from the first and second evaporator after refrigerant passes through a pulse width modulation switch valve operably and fluidly connected to both the first evaporator and the second evaporator.

16. An appliance comprising the refrigeration system of claim 1, wherein the refrigeration system is spaced within an appliance cabinet and a first evaporator is associated with a fresh food compartment of the appliance and operates at a first refrigerant fluid pressure level and a second evaporator is associated with a freezer compartment and operates at a second refrigerant fluid level; and wherein the switch valve of the refrigeration system is a pulse width modulation switch valve positioned without or within the compressor and the compressor is a linear compressor.

17. An appliance comprising: a cabinet comprising fresh food compartment having an interior and a freezer compartment having an interior; at least one door operably connected to the cabinet to allow a user to access the interior of the fresh food compartment, the interior of the freezer compartment or both the interior of the fresh food compartment and the interior of the freezer compartment; and a refrigeration system spaced within the cabinet for cooling the fresh food compartment and the freezer compartment comprising: a condenser; a linear compressor that is activated and deactivated by a pulse width modulation switching device; a pulse width modulation refrigerant flow switch; at least two evaporators operably connected in parallel with one another with at least one evaporator associated with the refrigerator compartment that operates at a first refrigerant fluid pressure and with at least one other evaporator associated with the freezer compartment that operates at a second refrigerant fluid pressure; and a plurality of refrigerant fluid conduits operably connecting the condenser, the linear compressor and the evaporators into a refrigerant fluid flow circuit and such that the evaporators are capable of running simultaneously at different pressure levels and refrigerant flows from the evaporators, to the pulse width modulation refrigerant flow switch and through the pulse width modulation refrigerant flow switch such that the output fluid pressure from the pulse width modulation refrigerant flow switch that is delivered to a compressor chamber is between the first refrigerant fluid pressure and the second refrigerant fluid pressure.

18. The appliance of claim 17, wherein refrigerant is received from the pulse width modulation refrigerant flow switch into the compressor through a single inlet of the compressor.

19. The appliance of claim 17, wherein the compressor is an oil-less compressor and the refrigeration system further comprises at least one by-pass valve positioned within the refrigerant fluid circuit prior to fluid entering each evaporator to regulate flow of refrigerant into the evaporators.

20. The appliance of claim 17, wherein the pulse width modulation refrigerant control switch is configured to switch at a rate of once every about 30 seconds or faster.

21. A method of operating a refrigeration system comprising the steps of: activating a single linear compressor using a pulse width modulation switch such that the single linear compressor compresses refrigerant fluid and supplies compressed refrigerant fluid to a single condenser via fluid conduits from the compressor outlet; supplying compressed refrigerant fluid to a plurality of evaporators via fluid conduits such that each evaporator is fluidly connected to the condenser and wherein each of the evaporators are connected in parallel and configured to operate simultaneously at different refrigerant fluid pressures with one evaporator having a highest evaporator operating pressure and one other evaporator having a lowest evaporator operating pressure using refrigerant from the single linear compressor and wherein a first evaporator is associated with a first appliance food compartment and a second evaporator is associated with a second appliance food compartment; and recirculating refrigerant fluid back to the single linear compressor using a pulse width modulation refrigerant control valve that receives refrigerant fluid from the plurality of evaporators and supplies a return refrigerant fluid pressure level of refrigerant fluid to the compressor via a compressor inlet that is at a pressure between the highest evaporator operating pressure and the lowest evaporator operating pressure.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is a perspective view of a side-by-side refrigerator freezer incorporating the multiple evaporator system;

[0015] FIG. 2 is a schematic view of the components of the multiple evaporator system of the present invention;

[0016] FIG. 3 is a schematic view of a pulse width modulation valve having two intake valves with a single outlet switching to different stages/settings to allow fluid to flow through one intake at a time; and

[0017] FIGS. 4a-4c are staged in-line views of a three-way intake valve with a single outlet used in connection with a single suction compressor line showing a switching system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0018] For the purposes of description herein, the terms upper, lower, right, left, rear, front, vertical, horizontal, and derivatives thereof shall relate to the invention as oriented in FIG. 1. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in following specification, are simply exemplary embodiments. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be construed as limiting, unless expressly stated otherwise.

[0019] Referring initially to FIG. 1, there is shown a refrigerator 10 according to an aspect of the present invention. This aspect includes a side-by-side refrigerated cabinet section 12 and a freezer cabinet section 14 (behind the door 18). The refrigerator 10 includes side walls 11 and 13, respectively, and a rear wall 15. The refrigerator also typically includes at least one mullion that partially defines the refrigerated cabinet section(s) and the freezer cabinet(s) section(s). When more than two cabinet sections are formed, typically additional mullion wall sections are utilized. Refrigerator 10 also includes at least one closure door 16 for the refrigerator cabinet section 12, which is hinged to refrigerator cabinet section 12 and at least one freezer door 18 hinged to the freezer cabinet section 14. Both doors 16 and 18 include suitable seals for providing an airtight, or at least substantially airtight, thermally insulated sealed connection between the doors and respective cabinets. Although a side-by-side refrigerator/freezer 10 is illustrated in FIG. 1, other configurations, such as bottom mount freezer (including French door bottom mount freezers), top mount freezer configurations, may also be employed. Any systems with a third pull-out compartment or for that matter any number of separately coated compartments each typically with their own associated evaporator may be used. The compartments may be separate compartments within narrow cabinet sections or separate cabinet sections accessible by opening an access door 16, 18, for example, to access the interior volume of the cabinet. The present invention can be employed with any configuration of a refrigerator/freezer combination or any other multiple zone refrigeration device.

[0020] Refrigerator 10 is adapted to receive and/or be capable of receiving a variety of shelves and modules at different positions defined by, in the embodiment shown in FIG. 1, a plurality of horizontally spaced vertical rails 22 extending from the rear wall 15 of the refrigerator and freezer cabinet sections 12, 14. In the embodiment shown, the supports are in the form of vertically extending rails 22 with vertically spaced slots for receiving mounting tabs on shelf supports 23 and similar tabs on modules, such as modules 20 (crisper), 24 (crisper), 25 (shelf unit), and 26 (drawer), for attaching the modules in cantilevered fashion to the cabinet sections 12, 14 at selected incrementally located positions. The inside edges of doors 16 and 18 also include vertically spaced shelf supports, such as 27, for positioning and engaging bins 30 and modules, such as 32, in the doors, in particular within the pocket of the door defined by the liner 34. The shelves, modules, bins, and the like, can be located at a variety of selected locations within the cabinet sections 12 and 14 and doors 16 and 18 to allow the consumer to select different locations for convenience of use.

[0021] Some of the modules in refrigerator 10, such as modules 20 and 32, may be powered modules or components and therefore require operating utilities. Thus, for example, module 20 may be a powered crisper or an instant thaw or chill module and may require utilities, such as cooled or heated fluids or electrical operating power and receive these utilities from the appliance. Other modules, such as module 26, may likewise require operational utilities while modules, such as a passive crisper module, would not. Door modules also, such as module 32, may, for example, include a water dispenser, vacuum bag sealer or other accessory conveniently accessible either from the outside of door 16 or from within the door and likewise may receive operating utilities from conduits, such as disclosed in application Ser. No. 12/469,915 filed May 21, 2009, entitled REFRIGERATOR MODULE MOUNTING SYSTEM; and Ser. No. 12/469,968 filed May 21, 2009, entitled MULTIPLE UTILITY RIBBON CABLE. The disclosures of these patent applications are incorporated herein by reference in their entirety. While not shown in the Figures, the modules may also be used for quick cooling of beverages, quick freezing/chilling of other food stuffs or even making of ice, ice pieces (cubes), or frozen products.

[0022] Contained within the insulated cabinets of the refrigerator are the usual freezer and fresh food evaporator, condenser, and the usual fluid couplings to a compressor for the operation of the refrigerator. Refrigerator 10 of this invention, however, includes additional fluid circuits for supplying at least a dual evaporator system. The refrigeration system according to an aspect of the present invention incorporates a multiple evaporator system having a pulse-width-modulation (PWM) switch valve as shown generally in the schematic diagram of FIG. 2, now described.

[0023] The schematic diagram of FIG. 2 shows the locations of various major components of the refrigerator and thermal storage system in no particular relationship within the refrigerator cabinet, it being understood that, in practice, these elements can be located in any conventional or convenient location. For example, the condenser may conventionally be located in the back outside wall of the cabinet or in a compartment above cabinet sections 12, 14. Thus, the schematic diagram of FIG. 2 is illustrative only and does not limit the position of any of the components.

[0024] In FIG. 2, refrigerator 10 of an aspect of the present invention incorporates a linear compressor 40. The linear compressor is a variable capacity compressor. The linear compressor is also typically an oil-less compressor. Due primarily to its relatively flat elongated shape, and the oil-less nature of the linear compressor, it can be located conveniently at nearly any location within the refrigerator in any orientation within the cabinet, including in the space between the refrigerator inner liner and its outer shell. The compressor is typically located near the top of the refrigerator near the condenser where heat can be evacuated upwardly and away from the refrigerator cabinet. One type of compressor, the compressor 40 can be of the type described in U.S. patent application Ser. No. 10/553,944 filed Apr. 22, 2004, entitled SYSTEM FOR ADJUSTING RESONANT FREQUENCIES IN A LINEAR COMPRESSOR and published as U.S. Patent Application Publication No. 2006/0110259 on May 25, 2006. The disclosure of this application and publication are incorporated herein by reference in their entirety. While not preferred, any other type of compressor may also be employed in connection with the present invention including a standard reciprocations compressor. A linear compressor is presently used to allow the system to even more dynamically adjust to changing thermal loads because the stroke length of the compressor can be quickly regulated to match cooling needs and increase cooling capacity of the overall system. Such dynamic adjustments are not possible with a standard compressor versus a variable capacity compressor, in particular a linear compressor.

[0025] Refrigerators typically cycle on and off depending upon the frequency of use, the refrigerator content, and the surrounding environmental conditions. With conventional refrigerators, the refrigerator compressor runs at maximum capacity regardless of load demands. This results in the utilization of a significant amount of excess energy, which is environmentally wasteful and expensive for the consumer. Linear compressors, such as disclosed in U.S. Patent Application Publication No. 2006/00110259, are capable of a variable operating capacity. Linear compressors, thus, can be controlled to meet the actual demand for refrigerators, but also have the benefit of operating at a higher capacity than conventional rotary compressors. Additionally, the capacity to compression work ratio of linear compressors according to an aspect of the present invention, can be amplified beyond that of a reciprocating compressor, thus providing a further favorable energy efficient operational condition.

[0026] For systems having multiple evaporators (2 or more), a priority sequence is generally used in a controller apparatus to control the priority of the evaporators' run times, such that the compressor receives a consistent inlet pressure from the evaporator system wherein a running evaporator can have a different evaporation pressure than the other evaporators in the system. Current compressors are not able to operate with different inlet pressures from multiple evaporators at the same time. Currently, in a multiple evaporator system, when one evaporator is working, the second, third, or fourth evaporator needs to stop so as not to send differing inlet pressures to the compressor. In such a system, it is necessary to implement a complex control strategy to determine evaporator priority along with complex valve systems in place to avoid compressor problems and system loss.

[0027] As shown in FIG. 2, a compressor 40 is operably coupled to and part of an overall refrigeration circuit 60 including coolant fluid conduit 42 which couples the compressor 40 to a condenser 44. In the exemplary system shown in FIG. 2, a plurality of evaporators 49, 50, 51, are used to cool the fresh food compartment, the freezer compartment, and a component compartment (such as modules 20 and 32 as shown in FIG. 1), respectively. While three evaporators are shown in FIG. 2, two or more may be employed in any given design. In order to cool the various compartments of the refrigerator 10, the condenser 44 directs refrigerant flow through the refrigeration circuit 60 toward the plurality of evaporators. In the embodiment shown in FIG. 2, a system of valves is comprised of a plurality of bypass valves 48 which are moveable between an opened position and a closed position. The valves 48 are either opened to allow refrigerant to flow to the associated evaporator, or closed to bypass the flow of refrigerant to the associated evaporator. The valve system controls the bypass valves 48 based on a demand signal, such that the valves 48 are selectively operated by a microprocessor-based control circuit to either allow the flow of refrigerant to the associated evaporator, or bypass the flow of refrigerant to the associated evaporator. The valve system operation is based on the thermal demand of the cabinets sections 12, 14 and an associated component.

[0028] As shown in FIG. 2, any metering device such as a thermostatic expansion valve 47 shown in the refrigeration circuit 60 preceding the fresh food evaporator 49 may be employed. The optional thermostatic expansion valve 47 or other metering device may be positioned in the refrigeration circuit prior to refrigerant entering any one, any combination, or all of the plurality of evaporators 49, 50, 51. Instead of a thermoelectric expansion valve, a compartment capillary device 46 can be used prior to any evaporator of the system, as shown in FIG. 2, preceding the freezer compartment evaporator 50 and the compartment evaporator 57.

[0029] The compressor 40 further comprises at least one inlet 41, but could have a plurality of two or more inlets 41 and an outlet 43. The evaporators 49, 50, 51 have an inlet pressure side 55 and an outlet pressure side 56. An optional four-way valve 45 is shown linking the coolant fluid conduit from the condenser and the coolant fluid conduit that supplies coolant to the evaporators. If only two evaporators were employed, a three-way valve may be used. A series of valves could also be used so long as coolant fluid is delivered to each evaporator. Optionally, these valves could be configured to be controlled to regulate coolant fluid flow. The optional bypass valves 48 send refrigerant through conduits of the refrigeration circuit 60 to the inlet pressure side 55 of the associated evaporator when the valves 48 are in the open position. After an evaporator finishes cooling a zone of the refrigerator 10, the remaining refrigerant exits the evaporator via the outlet pressure side 56. The refrigerant .then moves through suction refrigerant fluid conduit lines 57, 58, 59 depending on the evaporator(s) in use. The system shown in FIG. 2 is capable of running all three evaporators simultaneously, such that all valves 48 can be in the open position to supply refrigerant to the evaporators 49, 50, 51 and remaining refrigerant will then flow through suction lines 57, 58, 59 at the same or at variable pressures. Similarly, any two evaporators can be in operation simultaneously or one evaporator can be in operation at a given time. The suction lines 57, 58 and 59 send refrigerant from the outlet pressure sides 56 of the associated evaporators to a pulse-width-modulation (PWM) switch valve 52 which then sends a pressure of refrigerant between the outlet pressure side having the highest pressure and the outlet pressure side with the lowest pressure (when only two suction lines are fed into the PWM valve (see FIG. 3) the valve sends an approximately average pressure or the average pressure of the two suction lines) to the compressor inlet 41 via suction line 61. In this way, a single compressor, preferably a variable capacity compressor, and more preferably a linear compressor and typically a single condenser can efficiently and effectively run a multiple (two or more) evaporator system even when the pressure exiting any one evaporator is varied as compared to another evaporator in the system as described below.

[0030] Pulse-width-modulation is a technique used for controlling power to electrical devices, such as the PWM switch valve 52 (best shown in FIGS. 3 and 4a-4c). As shown in FIG. 3, the switch valve can be turned on and off at a fast pace, typically about 30 seconds or less or exactly 30 seconds or less, more typically about 0.5 seconds or less or exactly 0.5 seconds or less, and most typically about 10 milliseconds or less or exactly 10 milliseconds or less (or any time interval from about 30 seconds or less), via a pulse-width-modulation signal sent from a controller using a control signal such as a direct current signal, digital signal or serial control. The rapid switching time interval can by dynamically adjusted based upon a given cooling demand for a portion of the appliance serviced by any individual appliance compartment or device. The rapid switching also allows the system to dynamically adjust to changing thermal load conditions of a given section of the appliance, typically based upon use of the appliance, most typically thermal load changes brought about by a user accessing one of the cabinet sections by opening one or more of the doors. The rapid switching allows for the system to pull refrigerant from all circuits, but allows for more of the refrigerant flow to travel through the evaporator serving the cabinet section or compartment associated with the highest thermal load and needing the added cooling capacity at the time. The rapid switching between the refrigerant flow lines at the rates described above cause the refrigerant flow lines to operate sequentially and allows the system to emulate and behave as a system that has the evaporators configured in parallel with one another.

[0031] As shown in FIG. 3, the PWM valve 52 may be within the compressor housing (dashed line 70 or outside the compressor housing 70). An electrical solenoid PWM valve (two intake in FIG. 3 and rotating three intake version in FIGS. 4a-c) regulates the suction lines coolant is permitted to flow through, one suction line at a time. In the valve shown in FIG. 3, blocking member 72 is moved by the electromagnetic action between the suction line intakes, in FIG. 3, between the refrigerant compartment section suction line (shown open) and the freezer compartment section suction line (shown closed). The PWM valve 52 shown in FIGS. 4a-c operates by rotating a generally butterfly-shaped blocking member 82 rotates about a central axis 84 to allow refrigerant fluid flow from any one of three intakes 86 in the embodiment of FIG. 4. While an electrical solenoid valve is typically used, other valves that enable rapid switching such as pneumatic valves, hydraulic valves, or mechanical valves may also be used. The spring-biased valves 74 and 76 of the compressor allow for coolant flow into and out of the piston chamber 78. The compressor piston 80 compresses the coolant fluid in the chamber 78. When the piston is drawn back fluid flows through valve 74 and when the piston 80 moves toward the valves 74 and 76, valve 76 opens and delivers refrigerant fluid out of the compressor.

[0032] A pulse-width-modulation signal can also be sent to the compressor in response to refrigerant demand in the refrigerator system. The pulse-width-modulation signal to the compressor allows for a fast paced load on and load off signal to be sent to the compressor resulting in a duty cycle somewhere between 100% and 0% allowing for better matching of load with evaporator/compartment cooling needs. A linear compressor, as used in the present invention, is particularly well adapted to a fast paced load on and load off signal due to the linear nature of the piston stroke of the linear compressor. In this way, the linear compressor of the present invention can run at a higher frequency and work closer to a maximum coefficient of performance using the pulse-width-modulation to turn the compressor on and off frequently and quickly. The pulse-width-modulation signal sent to the PWM switch valve 52 is designed to switch frequently and efficiently to send a coolant fluid pressure level between the highest suction pressure line and the lowest suction pressure lines' pressure levels to the compressor after having received varied pressures from the multiple evaporators in the system. Operating in this manner increases the system's coefficient of performance (COP) and achieves maximum compressor efficiency for supplying cooling to the refrigerator during times of high demand, lower demand, or during times of instantaneous demand for cooling in multiple zones. The controller uses pulse-width-modulation to modulate the compressor between a high capacity duty cycle (100%) and a low capacity duty cycle (0%). When greater cooling capacity is needed the system can operate at a higher capacity to match the need and do so dynamically through the use of a variable capacity (linear compressor) and the PWM switch valve 52.

[0033] The design of the present invention allows the compressor to operate more efficiently and keep all evaporators working at the same time, i.e. in parallel, thereby reducing system losses and avoiding the need for a complex control. The PWM switch valve is designed to switch very quickly between the evaporators (typically dynamically switching each about 0.01 seconds to about 30 seconds depending on cooling demand), thereby allowing the compressor inlet pressure to be an evaporator pressure average (when two evaporators are employed and between the highest pressure of the highest operating pressure evaporator and the lowest operating pressure of the lowest operating pressure evaporator, but typically approximately the average, when more than two evaporators are employed in the system. The pressure will be variable between the pressure of the highest operating pressure evaporator and the lowest operating pressure evaporator in the system. The pressure will vary based upon the percentage of time fluid flow is allowed through each evaporator by the PWM valve which increases the system's coefficient of performance.

[0034] It will become apparent to those skilled in the art that various modifications to the preferred embodiments of the invention as described herein can be made without departing from the spirit or scope of the invention as defined by the appended claims.