Ice dispenser system for a refrigeration appliance, refrigeration appliance, and method of making ice   

Abstract: An ice dispenser system for a refrigeration appliance includes an ice maker located within the refrigeration appliance for making ice cubes. The ice maker has an ice making state and a paused state. An ice bucket is located within the refrigeration appliance located so as to receive the ice cubes from the ice maker. The ice bucket is removably securable in the refrigeration appliance in an ice-making position. A sensor is located within the refrigeration appliance, the sensor sensing and providing a signal as to whether the ice bucket is in the ice making position. The ice maker is placed in the ice making state only when the sensor provides a signal that the ice bucket is in the ice making position. A related refrigeration appliance and method of making ice are also disclosed.

FIELD OF THE INVENTION

The subject matter disclosed herein relates to an ice dispenser system, a refrigeration appliance, and a method of making ice wherein an ice maker is halted if portions of the ice making assembly are not installed correctly.

BACKGROUND OF THE INVENTION

Various ice maker designs have been proposed for refrigeration appliances such as commercial or home refrigerators and/or freezers. In certain automatic ice makers, water is provided from an external source to a chilled ice cube mold. Once the water freezes into ice, the ice cubes in the mold are harvested and the cycle is repeated. Ice cube removal can be assisted by a brief heating of the mold to separate the ice cubes from the mold, if desired. Often, a sensor is present to detect an ice level in the ice bucket as ice builds up in the ice bucket as the cycle progresses. If the ice level in the bucket reaches a certain predetermined amount (i.e., the ice bucket is full), the cycle is halted until ice is removed from the ice bucket thereby lowering the ice level. In many refrigeration appliances, this cycle repeats automatically until the ice level sensor indicates a full ice bucket.

While such systems generally work well and as intended to provide a constant supply of ice and full ice bucket when desired, user misuse can cause certain issues. For example, if a user fails to return an ice bucket to its proper location within the refrigeration appliance, the ice making cycle may deposit ice in an undesired location within the refrigeration appliance. Further, the ice level sensor within the ice bucket may not operate properly to stop ice creation at the most optimum time. Therefore, an improved ice making and dispensing system that provides an even more reliable supply of ice, only when and where desired, would be welcome.

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

According to certain aspects of the disclosure, an ice dispenser system for a refrigeration appliance includes an ice maker located within the refrigeration appliance for making ice cubes. The ice maker has an ice making state and a paused state. An ice bucket is located within the refrigeration appliance located so as to receive the ice cubes from the ice maker. The ice bucket is removably securable in the refrigeration appliance in an ice-making position. A sensor is located within the refrigeration appliance, the sensor sensing and providing a signal as to whether the ice bucket is in the ice making position. The ice maker is placed in the ice making state only when the sensor provides a signal that the ice bucket is in the ice making position. Various options and modifications are possible.

According to certain other aspects of the disclosure, a refrigeration appliance includes a refrigerated cabinet and an ice maker located within the refrigerated cabinet for making ice cubes. The ice maker has an ice making state and a paused state. An ice bucket is located within the refrigerated cabinet located so as to receive the ice cubes from the ice maker. The ice bucket is removably securable in the refrigerated cabinet in an ice-making position. A sensor is located within the refrigerated cabinet, the sensor sensing and providing a signal as to whether the ice bucket is in the ice making position. The ice maker is placed in the ice making state only when the sensor provides a signal that the ice bucket is in the ice making position. Again, various options and modifications are possible.

According to certain other aspects of the invention, a method of controlling an ice maker for a refrigeration appliance with a removable ice bucket includes sensing whether the ice bucket is in an ice making position, operating the ice maker to make ice if the sensing step senses that the ice bucket is in the ice making position, and halting operation of the ice maker if the sensing step senses that the bucket is not in the ice making position. As above, various options and modifications are possible.

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

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 provides a front view of a refrigeration appliance with its doors closed;

FIG. 2 provides a front view of the refrigeration appliance of FIG. 1 with its doors opened;

FIG. 3 provides a partially exploded perspective view of an ice making assembly according to certain aspects of the present disclosure;

FIG. 4 provides a view of the ice making assembly of FIG. 3 with the ice bucket in the housing;

FIG. 5 is a schematic view of the ice making assembly of FIG. 3 showing an electromechanical sensor;

FIG. 6 is a schematic view as in FIG. 5, showing a weight sensor;

FIG. 7 is a schematic view as in FIG. 5, showing an optical sensor; and

FIG. 8 is a flow chart outlining one possible method of operation for the disclosed systems.

DETAILED DESCRIPTION

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 is a perspective view of an exemplary refrigeration appliance 10 depicted as a refrigerator in which ice-making assemblies in accordance with aspects of the present invention may be utilized. It should be appreciated that the appliance of FIG. 1 is for illustrative purposes only and that the present invention is not limited to any particular type, style, or configuration of refrigeration appliance, and that such appliance may include any manner of refrigerator, freezer, refrigerator/freezer combination, and so forth.

Referring to FIG. 2, the refrigerator 10 includes a fresh food storage compartment 12 and a freezer storage compartment 14, with the compartments arranged side-by-side and contained within an outer case 16 and inner liners 18 and 20 generally molded from a suitable plastic material. In smaller refrigerators 10, a single liner is formed and a mullion spans between opposite sides of the liner to divide it into a freezer storage compartment and a fresh food storage compartment. The outer case 16 is normally formed by folding a sheet of a suitable material, such as pre-painted steel, into an inverted U-shape to form top and side walls of the outer case 16. A bottom wall of the outer case 16 normally is formed separately and attached to the case side walls and to a bottom frame that provides support for refrigerator 10.

A breaker strip 22 extends between a case front flange and outer front edges of inner liners 18 and 20. The breaker strip 22 is formed from a suitable resilient material, such as an extruded acrylo-butadiene-styrene based material (commonly referred to as ABS). The insulation in the space between inner liners 18 and 20 is covered by another strip of suitable resilient material, which also commonly is referred to as a mullion 24 and may be formed of an extruded ABS material. Breaker strip 22 and mullion 24 form a front face, and extend completely around inner peripheral edges of the outer case 16 and vertically between inner liners 18 and 20.

Slide-out drawers 26, a storage bin 28 and shelves 30 are normally provided in fresh food storage compartment 12 to support items being stored therein. In addition, at least one shelf 30 and at least one wire basket 32 are also provided in freezer storage compartment 14.

The refrigerator features are controlled by a controller 34 according to user preference via manipulation of a control interface 36 mounted in an upper region of fresh food storage compartment 12 and coupled to the controller 34. As used herein, the term “controller” is not limited to just those integrated circuits referred to in the art as microprocessor, but broadly refers to computers, processors, microcontrollers, microcomputers, programmable logic controllers, application specific integrated circuits, and other programmable circuits, and these terms are used interchangeably herein.

A freezer door 38 and a fresh food door 40 close access openings to freezer storage compartment 14 and fresh food storage compartment 12. Each door 38, 40 is mounted by a top hinge 42 and a bottom hinge (not shown) to rotate about its outer vertical edge between an open position, as shown in FIG. 1, and a closed position. The freezer door 38 may include a plurality of storage shelves 44 and a sealing gasket 46, and fresh food door 40 also includes a plurality of storage shelves 48 and a sealing gasket 50.

The freezer storage compartment 14 may include an automatic ice maker 52 and a dispenser 54 provided in the freezer door 38 such that ice and/or chilled water can be dispensed without opening the freezer door 38, as is well known in the art. Doors 38 and 40 may be opened by handles 56 is conventional. A housing 58 may hold a water filter 60 used to filter water for the ice maker 52 and/or dispenser 54.

As with known refrigerators, the refrigerator 10 also includes a machinery compartment (not shown) that at least partially contains components for executing a known vapor compression cycle for cooling air. The components include a compressor, a condenser, an expansion device, and an evaporator connected in series as a loop and charged with a refrigerant. The evaporator is a type of heat exchanger which transfers heat from air passing over the evaporator to the refrigerant flowing through the evaporator, thereby causing the refrigerant to vaporize. The cooled air is used to refrigerate one or more refrigerator or freezer compartments via fans. Also, a cooling loop can be added to direct cool the ice maker to form ice cubes, and a heating loop can be added to help remove ice from the ice maker. Collectively, the vapor compression cycle components in a refrigeration circuit, associated fans, and associated compartments are conventionally referred to as a sealed system. The construction and operation of the sealed system are well known to those skilled in the art.

FIGS. 3-5 show one example of an ice dispenser system 70 according to certain aspects of the invention. As shown therein, ice dispenser system 70 is a door-mounted system. Accordingly, ice dispenser system 70 would typically be mounted on freezer door 38. However, aspects of the present disclosure are also applicable to systems mounted elsewhere, whether on a door or elsewhere within a refrigerated compartment. Accordingly, the depicted location on freezer door 38 or within freezer compartment 14 are not limiting.

As shown, ice dispenser system includes a conventional ice maker assembly 72, an ice bucket assembly 74, and a dispensing motor assembly 76. These elements are mounted to a housing 78 attached to door 38.

Ice maker 72 may be a conventional automatic icemaker that makes a number of ice cubes at a time automatically from a water source. Ice maker 72 may therefore make 6-8 cubes per cycle, and over 100 ice cubes per day, for example, in ice molds 80. Ice cubes are dumped periodically into ice bucket assembly 74 in a conventional fashion. A feeler arm 82 may be provided as a shut off in case ice bucket assembly becomes full or clogged. Accordingly, if an ice cube level in bucket assembly reaches feeler arm 82 causing it to move, then ice maker 72 may be automatically shut off by controller 34. Similarly, if a user manually moves the feeler arm 82 to the shut off position ice maker 72 may shut off. Therefore, ice maker 72 as described is conventional and any variety of automatic ice makers for supplying ice bucket assembly 74 could be used.

Ice bucket assembly 74 includes an ice bucket 84 having a base 86 with an opening 88 in it for dispensing ice when desired by a user. Ice bucket assembly 74 may further include a rotatable internal arm 90 for assisting in moving ice cubes down and through opening 88 when desired and for breaking up and clumped together ice cubes. A motor (not shown) located within dispensing motor assembly 76 has a drive mechanism 92 which engages a complimentary receiver 94 in ice bucket assembly 74 for rotating arm 90 within ice bucket 84.

Typically, a cover such as plate 96 is provided to shield the motor from moisture above and within ice bucket 94. Plate 96 has an opening 98 corresponding to opening 88 at the base of ice bucket 84. A trap door 100 may be provided in housing 78, either spring loaded to a closed position to be opened by the gravitational force of dispensed ice cubes or mechanically opened for dispensing. Trap door 100 keeps cold air in the freezer compartment 14.

When a user operates a button 99 or paddle (not shown) within dispenser 54 indicating a desire for ice cubes, trap door 100 can open or be opened, the motor can operate internal arm 90 (or auger or other device) within ice bucket 84, etc., to dispense ice to a user. Again, various configurations and locations for these items are possible, and use of various conventional designs for in-door and in-compartment ice makers and buckets are possible.

As shown in FIG. 3, a sensor 110 may be located within refrigeration appliance 10 to sense and provide a signal as to whether ice bucket 84 is properly installed in its ice making position. Sensor 110 may be for example a mechanical switch that is moved upon installing ice bucket properly. Sensor 110 may be located at various locations within housing 78 so as to be contacted and displaced by ice bucket 84 when installed. As shown, sensor 110 is located in a location extending through motor cover plate 96.

Sensor 110, ice maker 74, its water source (not shown), and all moving parts described above may be connected to a controller such as controller 34 or a separate controller within refrigeration appliance 10. Accordingly, ice maker 74 may only be placed in a ice making state if sensor 110 provides a signal to the controller that ice bucket 84 is in the ice making position within housing 78. Ice maker 74 will not operate if ice bucket 84 is not present at all or is not inserted fully or properly into housing 78. If desired, an indicator 112 such as a light may be placed within or on the front of the refrigeration appliance to indicate that ice bucket sensor 110 has (or has not) sensed that ice bucket 84 is in the ice making position. The indicator may also include a speaker to provide an audible notice (a periodic beep, for example) to a user that the ice bucket is not in place.

FIG. 5 shows a schematic view of placement of sensor 110 within housing 78, pivotably extending though a surface 114 of plate 96. Again, it should be understood that sensor 110 could be anywhere within housing 78 impacted by a properly inserted ice bucket, such as surfaces 116, 118, 120, 122, 124, etc. Sensor 110 as shown is a pivoting electromechanical switch type device, although it could also be a push button, spring and/or reed switch, potentiometer, or any other electromechanical type device.

FIG. 6 shows an alternate sensor 126 located so as to sense a weight of an ice bucket. Sensor 126 could therefore comprise a strain gauge, piezoelectric device, pressure mat, or any other electronic weight sensing device. Sensor 126 could be located on any surface within housing 78 that would bear weight from a properly inserted ice bucket, and should be sensitive enough and/or oriented properly to sense an empty bucket.

FIG. 7 shows another alternate sensor 126, in this case an optical device. Optical sensor 126 has a transmitter 128 and a receiver 130. Optical sensor 126 should again be located so that receiver does not sense the presence of the ice bucket until properly and fully inserted.

FIG. 8 shows one possible control algorithm for ice dispenser assemblies according to the present disclosure. As shown therein, when the refrigeration appliance is turned on the system is at start position 200. The ice making unit is turned on at step 202 by the controller responsible for doing so. Ice making is thus initiated 204. At step 206, the signal from the ice bucket sensor is evaluated by the controller and a decision is made at step 208. If the ice bucket is in position, the ice making unit remains on and ice production is continued 204. As long as the ice bucket sensor keeps noting that the ice bucket is in place, ice making continues. Ice making may be stopped for other reasons, for example in case of an ice bucket full signal (not shown) or the like. If however, a signal is not received from the ice bucket sensor that the ice bucket is in place, the controller sends a signal 212 to the ice maker and the ice maker is turned off 214. Optionally, a signal 216 may also be provided to a user by way of a light on the front of the refrigeration appliance, audible signal, etc. that the ice bucket is not in place.

In view of the above, an ice dispenser assembly, a refrigeration appliance and a method of operating an ice dispenser assembly are provided where beneficially ice is not made if an ice bucket is not properly inserted in place to receive ice from an ice maker. A controller receives signals from a sensor as to whether the ice bucket is in place. If the ice bucket is not in place, the controller places the ice maker in a standby state and does not place the ice maker in an ice making state. No further ice cubes are dumped into an ice bucket from the ice maker unless and until the ice bucket sensor senses that the ice bucket has been placed. Such sensor-based system can work with ice buckets located in a door, compartment, surface, shelf, or anywhere else for that matter.

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 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 languages of the claims.