U.S. patent application number 12/005997 was filed with the patent office on 2009-07-02 for icemaker combination assembly.
Invention is credited to William T. Moon, Paul Robert Surowiec, Mark Wayne Wilson.
Application Number | 20090165492 12/005997 |
Document ID | / |
Family ID | 40796481 |
Filed Date | 2009-07-02 |
United States Patent
Application |
20090165492 |
Kind Code |
A1 |
Wilson; Mark Wayne ; et
al. |
July 2, 2009 |
Icemaker combination assembly
Abstract
In accordance with the present disclosure, an icemaker
combination assembly is provided and comprises a refrigerator
having a freezer compartment and a fresh food compartment. The
freezer compartment can have a freezer door assembly and the fresh
food compartment can have a fresh food door assembly. The icemaker
combination further comprises a first icemaker having a first ice
cube storage bin disposed within the freezer compartment and a
second icemaker having a second ice cube storage bin disposed
within the fresh food compartment. The first and second icemakers
having a production activation level selected from the group
consisting of the first icemaker active only, the second icemaker
active only, the first and the second icemakers both active, and
the first and the second icemakers both inactive. The first and
second icemakers can selectively and simultaneously produce and
independently store ice.
Inventors: |
Wilson; Mark Wayne;
(Simpsonville, KY) ; Moon; William T.;
(Taylorsville, KY) ; Surowiec; Paul Robert;
(Louisville, KY) |
Correspondence
Address: |
Fay Sharpe LLP
1228 Euclid Avenue, 5th Floor, The Halle Building
Cleveland
OH
44115
US
|
Family ID: |
40796481 |
Appl. No.: |
12/005997 |
Filed: |
December 28, 2007 |
Current U.S.
Class: |
62/344 |
Current CPC
Class: |
F25C 1/10 20130101; F25C
2305/022 20130101; F25C 5/046 20130101; F25C 2700/06 20130101; F25C
2400/06 20130101; F25C 2400/10 20130101; F25C 5/187 20130101; F25C
2700/12 20130101 |
Class at
Publication: |
62/344 |
International
Class: |
F25C 5/18 20060101
F25C005/18; F25C 1/00 20060101 F25C001/00; F25D 11/02 20060101
F25D011/02 |
Claims
1. A refrigerator having an icemaker combination assembly
comprising: said refrigerator having a freezer compartment and a
fresh food compartment, said freezer compartment having a freezer
door assembly and said fresh food compartment having a fresh food
door assembly; a first icemaker having a first ice cube storage bin
removably disposed within said freezer compartment; a second
icemaker having a second ice cube storage bin disposed within said
fresh food compartment; and, said first and said second icemakers
selectively simultaneously producing and independently storing
ice.
2. The refrigerator according to claim 1, wherein said second ice
cube storage bin is molded directly into said fresh food door
assembly.
3. The refrigerator according to claim 1, wherein said second ice
cube storage bin is fixedly attached to said fresh food door
assembly.
4. The refrigerator according to claim 1, wherein said second ice
cube storage bin is removeably disposed within a portion of said
fresh food door assembly.
5. The refrigerator according to claim 1, wherein said freezer
compartment is side-by-side with said fresh food compartment.
6. The refrigerator according to claim 1, wherein said freezer
compartment is a drawer situated below said fresh food
compartment.
7. The refrigerator according to claim 1, wherein said freezer
compartment is above said fresh food compartment.
8. A refrigerator having an icemaker combination assembly
comprising: said refrigerator having a freezer compartment and a
fresh food compartment, said freezer compartment having a freezer
door assembly and said fresh food compartment having a fresh food
door assembly; a first icemaker having a first ice cube storage bin
removably disposed within said freezer compartment; a second
icemaker having a second ice cube storage bin removably disposed
within said fresh food compartment; said first and said second
icemakers selectively simultaneously producing ice; and, said
second ice cube storage bin is selectively mounted onto said fresh
food door assembly for dispensing of the ice through said fresh
food door.
9. The refrigerator assembly according to claim 8, wherein said
first icemaker is selectively inactive while said second icemaker
is active for a first ice production level.
10. The refrigerator assembly according to claim 8, wherein said
first icemaker is selectively active while said second icemaker is
inactive for a second ice production level.
11. The refrigerator assembly according to claim 8, wherein said
first icemaker is selectively active while said second icemaker is
active for a third ice production level.
12. The refrigerator assembly according to claim 8, wherein said
first ice cube storage bin is molded into said freezer door
assembly for selective dispensing of the ice through said freezer
door.
13. The refrigerator assembly according to claim 8, wherein said
first ice cube storage bin is selectively mounted onto said freezer
door assembly for dispensing of the ice through said freezer
door
14. A refrigerator having an icemaker combination assembly
comprising: said refrigerator having a freezer compartment and a
fresh food compartment, said freezer compartment having a freezer
door assembly and said fresh food compartment having a fresh food
door assembly; a first icemaker having a first ice cube storage bin
disposed within said freezer compartment; a second icemaker having
a second ice cube storage bin disposed within said fresh food
compartment; and, said first and said second icemakers having a
production activation level selected from the group consisting of
said first icemaker active only, said second icemaker active only,
said first and said second icemakers both active, and said first
and said second icemakers both inactive.
15. The refrigerator assembly according to claim 14, wherein said
first icemaker having a first production level and said second
icemaker having a second production level, said first production
level different than said second production level.
16. The refrigerator assembly according to claim 15, wherein said
first ice cube storage bin and said second ice cube storage bin
removably disposed from said freezer compartment and said fresh
food compartment, respectively, for bulk dumping of the ice from
said bins.
17. The refrigerator assembly according to claim 15, wherein said
first ice cube storage bin is molded directly into said freezer
door assembly for selective dispensing of the ice through the
freezer door.
18. The refrigerator assembly according to claim 15, wherein said
second ice cube storage bin is molded directly into said fresh food
door assembly for selective dispensing of the ice through the fresh
food door.
19. The refrigerator assembly according to claim 18, wherein said
first ice cube storage bin is molded directly into said freezer
door assembly for selective dispensing of the ice through the
freezer door.
20. The refrigerator assembly according to claim 18, wherein a
relative positioning of said freezer compartment and said fresh
food compartment is selected from the group consisting of a
side-by-side arrangement, a bottom freezer arrangement, and a top
freezer arrangement.
Description
BACKGROUND
[0001] This disclosure relates generally to a plurality of
icemakers for a refrigerator and freezer combination appliance
having independent and dual ice production, storage, and
access.
[0002] A conventional automatic through-the-door icemaker in a
typical residential refrigerator appliance has three major
subsystems: an icemaker, a bucket with an auger and ice crusher,
and a dispenser insert in the freezer door that allows the ice to
be delivered to a cup without opening the door.
[0003] In one arrangement, a freezer can have a metal mold that
makes between six to ten ice cubes at a time. The mold is filled
with water at one end and the water evenly fills the ice cube
sections through weirs (shallow parts of the dividers between each
cube section) that connect the sections. Opening a valve on the
water supply line for a predetermined period of time usually
controls the amount of water. The temperature in the freezer
compartment is usually between about -10 degrees Fahrenheit to
about +10 degrees Fahrenheit. The mold can be cooled by conduction
with the freezer air, and the rate of cooling is enhanced by
convection of the freezer air, especially when the evaporator fan
is operating. A temperature-sensing device in thermal contact with
the ice cube mold generates temperature signals and a controller,
monitoring the temperature signals indicates when the ice is ready
to be removed from the mold. When the ice cubes are ready, a motor
in the icemaker drives a rake in an angular motion. The rake pushes
against the cubes to force them out of the mold. A heater on the
bottom of the mold is turned on to melt the interface between the
ice and the metal mold. When the interface is sufficiently melted,
the rake is able to push the cubes out of the mold. Because the
rake pivots on a central axis, the cross-sectional shape of the
mold typically is an arc of a circle to allow the ice to be pushed
out.
[0004] After the ice is harvested, a feeler arm, usually driven by
the same motor as the rake, is raised from and lowered into the
storage bucket. If the arm cannot reach its predetermined low
travel set point, it is assumed that the ice bucket is full and the
icemaker will not harvest until more ice has been removed from the
bucket. If the feeler arm returns to its low travel set point, the
ice making cycle repeats.
[0005] The ice storage bucket holds and transports ice to the
dispenser in either crushed or whole cube form. If a user requests
ice at the dispenser a motor drives an auger that pushes the ice to
the front of the bucket where a crusher is located. The position of
a door, controlled by a solenoid, determines whether or not the
cubes will go through the crusher or by-pass it and be delivered as
whole cubes. The crusher has sets of stationary and rotating blades
that break the cubes as the blades pass each other. The crushed or
whole cubes then drop into the dispenser chute.
[0006] The dispenser chute connects the interior of the freezer
with the dispenser and usually has a door, activated by a solenoid,
that opens when the user requests ice. The dispenser has switches
that permit the user to select crushed or whole cubes, or water to
be delivered to the glass. The dispenser may have a switch that
senses the presence of a glass and starts the auger motor and opens
the chute door.
[0007] Occasionally, the ice cubes that are stored in the storage
bucket fuse together in large clusters of cubes. These fused
clusters are much more difficult for the crusher to break up,
raising the crushing design requirements for the mechanism and
occasionally causing damage. Additionally, the designs of most
conventional icemaker systems use substantial portions of the
freezer compartment volume, typically 25%-30%.
[0008] Accordingly, there is a need in the art for an improved
icemaker combination assembly that provides convenient light usage
of ice, provides selectively enough ice to supply high demand, and
balances the icemaker volume requirements and resultant usable
storage volume, i.e. available space, in the freezer and fresh food
compartments.
SUMMARY OF THE DISCLOSURE
[0009] In accordance with one aspect of the disclosure, an icemaker
combination assembly is disposed within a refrigerator having a
freezer compartment, a fresh food compartment and respective
freezer and fresh food door assemblies. The icemaker combination
includes a first icemaker having a first ice cube storage bin
removably disposed within the freezer compartment and a second
icemaker having a second ice cube storage bin disposed within the
fresh food compartment. The first and second icemakers can
selectively and simultaneously produce and independently store
ice.
[0010] In accordance with another aspect of the disclosure, an
icemaker combination assembly comprises a refrigerator having a
freezer compartment and a fresh food compartment. The freezer
compartment can have a freezer door assembly and the fresh food
compartment can have a fresh food door assembly. The icemaker
combination further comprises a first icemaker having a first ice
cube storage bin removably disposed within the freezer compartment
and a second icemaker having a second ice cube storage bin
removably disposed within the fresh food compartment. The first and
second icemakers can selectively and simultaneously produce ice and
the second ice cube storage bin is selectively mounted onto the
fresh food door assembly for dispensing of the ice through the
fresh food door.
[0011] In accordance with still another aspect of the disclosure,
an icemaker combination assembly comprises a refrigerator having a
freezer compartment and a fresh food compartment. The freezer
compartment having a freezer door assembly and the fresh food
compartment having a fresh food door assembly. The icemaker
combination further comprises a first icemaker having a first ice
cube storage bin disposed within the freezer compartment and a
second icemaker having a second ice cube storage bin disposed
within the fresh food compartment. The combination first and second
icemakers having a production activation level selected from the
group consisting of the first icemaker active only, the second
icemaker active only, the first and the second icemakers both
active, and the first and the second icemakers both inactive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a front perspective view of a side-by-side
refrigerator with the access doors open;
[0013] FIG. 2 is a part schematic side elevational view of a
refrigerator including one exemplary embodiment of an ice maker
according to the instant disclosure;
[0014] FIG. 3 is a front perspective view of a bottom freezer
refrigerator with the access doors closed including dual
icemakers;
[0015] FIG. 4 is a front perspective view of a bottom freezer
refrigerator with one access door open showing one of the exemplary
icemakers;
[0016] FIG. 5 is a cross sectional view of another exemplary
embodiment of an icemaker; and,
[0017] FIG. 6 is a front perspective view of a bottom freezer
refrigerator with the access doors open showing both exemplary
icemakers.
DETAILED DESCRIPTION
[0018] FIG. 1 is a front perspective view of a side-by-side
refrigerator 10 including a freezer compartment 12 and a fresh food
compartment 14. Freezer compartment 12 and fresh food compartment
14 are arranged side-by-side. A side-by-side refrigerator such as
refrigerator 10 is commercially available from General Electric
Company, Appliance Park, Louisville, Ky. 40225.
[0019] Refrigerator 10 includes an outer case 16 and inner liners
18 and 20. The space between case 16 and liners 18 and 20, and
between liners 18 and 20, is typically filled with foamed-in-place
insulation. Outer case 16 normally is formed by folding a sheet of
a suitable material, such as pre-painted steel, into an inverted
U-shape to form the top and side walls of case 16. The bottom wall
of case 16 normally is formed separately and attached to the
sidewalls and to a bottom frame that provides support for
refrigerator 10. Inner liners 18 and 20 are typically molded from a
suitable plastic material to form freezer compartment 12 and fresh
food compartment 14, respectively. Alternatively, liners 18 and 20
may be formed by bending and welding a sheet of a suitable metal,
such as steel. The illustrative embodiment includes two separate
liners 18 and 20 as it is a relatively large capacity unit and
separate liners add strength and are easier to maintain within
manufacturing tolerances. In smaller refrigerators, a single liner
is formed and a mullion spans between opposite sides of the liner
to divide it into freezer compartment 12 and fresh food compartment
14.
[0020] A breaker strip 22 extends between the case front flange and
the outer front edges of liners 18 and 20. Breaker strip 22 is
formed from a suitable resilient material, such as an extruded
acrylo-butadiene-styrene based material (commonly referred to as
ABS).
[0021] The insulation in the space between liners 18 and 20 can be
covered by another strip of resilient material 24, which is
commonly referred to as the mullion. Mullion 24 is preferably
formed of an extruded ABS material. It will be understood that in a
refrigerator with a separate mullion dividing a unitary liner into
a freezer and fresh food compartment, the front face member of that
mullion corresponds to mullion 24. Breaker strip 22 and mullion 24
form a front face, and extend completely around the inner
peripheral edges of case 16 and vertically between liners 18 and
20. Mullion 24, insulation between compartments 12 and 14, and the
spaced wall of liners 18 and 20 separating compartments 12 and 14,
sometimes are collectively referred to as the center mullion
wall.
[0022] Shelves 26 and drawers 28 normally are provided in fresh
food compartment 14 to support items being stored therein.
Similarly, shelves 30 and wire baskets 32 or the like are provided
in freezer compartment 12. In addition, freezer compartment 12 also
typically includes an icemaker 34.
[0023] A freezer door 36 and a fresh food door 38 close the access
openings to freezer and fresh food compartments 12 and 14,
respectively. Each door 36, 38 is mounted by a top hinge 40 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
closing the associated storage compartment. Freezer door 36
typically includes a plurality of storage shelves 42 and fresh food
door 38 typically includes a plurality of storage shelves 44 and a
butter storage bin 46.
[0024] In accordance with one appliance arrangement, a refrigerator
200 (FIGS. 3 and 4) can include 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 (not shown), a condenser (not shown), an expansion
device (not shown), and an evaporator (not shown) connected in
series and charged with a refrigerant. The evaporator is a type of
heat exchanger which transfers heat from air passing over the
evaporator to a 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 (not shown).
[0025] Collectively, the vapor compression cycle components in a
refrigeration circuit, associated fans, and associated compartments
are referred to herein as a sealed system. The construction of the
sealed system is well known and therefore not described in detail
herein, and the sealed system is operable to force cold air through
the refrigerator.
[0026] In accordance with one embodiment of the instant disclosure,
a first icemaker assembly 100 (FIG. 2) can be disposed within a
fresh food compartment 214 (see FIGS. 3 and 4). It is to be
appreciated that the exemplary icemaker 100 is for illustrative
purposes only and is not limited to the specific icemaker described
hereinafter.
[0027] Icemaker assembly 100 includes a conveyor assembly 102, a
first motor 104 drivingly coupled to conveyor assembly 102, a
second motor 106 drivingly coupled to an ice crusher 108 and an
auger mechanism 109, a refill valve 110 positioned adjacent to
conveyor assembly 102, a first ice cube storage bin 112, and a
controller 116 electrically coupled to first motor 104 and second
motor 106.
[0028] Conveyor assembly 102 can be positioned within fresh food
compartment 214, for example, within a top portion of fresh food
compartment 214, defined by a fresh food liner 220 and fresh food
door 238 (FIGS. 3 and 4). Conveyor assembly 102 comprises at least
a front roller 120 and a rear roller 122 and a continuous flexible
conveyor belt 124 fitted in tension about front and rear rollers
120, 122. In one embodiment, flexible conveyer belt 124 is made of
a flexible polymer. In illustrative examples flexible conveyer belt
124 is made from a thermoplastic elastomer, butyl rubber,
chlorobutyl rubber, natural rubber, synthetic rubber, neoprene
rubber, polyurethane, ethylene-propylene-diene modified,
ethylene-propylene rubber, silicone rubber or the like. Silicone
rubber is particularly preferred.
[0029] A multiplicity of individual ice cube molds 126 are disposed
within or upon conveyor belt 124 for creation of individual ice
cubes 128 therein. Typically, ice cube molds 126 are molded
directly into the material of flexible conveyor belt 124. In an
alternative embodiment, ice cube molds 126 are made of a rigid
material and are fixedly attached to conveyor belt 124. The rigid
material can be, for example, polypropylene, polyethylene, nylon,
ABS, or the like.
[0030] Flexible conveyor belt 124 dimensions can vary depending
upon the size of fresh food compartment 214 and the desired ice
cube 128 output for a respective fresh food icemaker assembly 100.
Typically, a nominal linear length (l) of flexible conveyor belt
124 is in the range between about 12 inches to about 18 inches, a
nominal width (w) is in the range between about 3 inches to about 8
inches and a nominal depth (d) is in the range between about 0.5
inches to about 1.5 inches.
[0031] As discussed above, the number of separate ice cube molds
126 is dependent upon the desired ice making capacity, but a
nominal number of individual ice cube molds 126 is in the range
between about 20 to about 300 divided into a nominal number of rows
(r) in the range between about 10 to about 30 and a nominal number
of columns (c) in the range between about 2 to about 10. The
dimensions of an individual ice cube mold 126 can vary depending on
the size of ice cubes 128 desired but a nominal length (x) is in
the range between about 0.75 inches to about 2 inches, and a
nominal width (y) is in the range between about 0.5 inches to about
1.5 inches. Also, a variety of cube shapes can be used, including
any conventional or unconventional shapes.
[0032] First motor 104 (FIG. 2) is drivingly coupled to conveyor
assembly 102. When energized, first motor 104 drives rear roller
122 (or alternatively front roller 120) causing conveyor belt 124
to rotate rear-to-front. A portion of ice cube molds 126 face
generally upward during ice cube 128 formation. As conveyor belt
124 rotates forward over front roller 120, a portion of ice cube
molds 126 face generally downward and ice cubes 128 frozen within
are gravity fed into first ice cube storage bin 112. In one
embodiment, first ice cube storage bin 112 is disposed within fresh
food door 238 (FIG. 4). First ice cube storage bin 112 can be
molded directly into fresh food door assembly 238 or first ice cube
storage bin 112 can be fixedly attached to or removeably disposed
within a portion of fresh food door assembly 238. A harvester bar
129 can be positioned adjacent to front roller 120 so as to contact
a portion of each respective ice cube 128 (as ice cube molds 126
rotate forward over front roller 120) and assist ice cubes 128 to
eject from ice cube molds 126.
[0033] As shown best in FIG. 2, the position of front roller 120 is
aligned with a top portion 130 of first ice cube storage bin 112
(when fresh food door 238 is in a closed position) such that ice
cubes 128 frozen within conveyor belt 124 are gravity fed into
first ice cube storage bin 112 as conveyor belt 124 rotates forward
over front roller 120.
[0034] Refill valve 110 is positioned within fresh food compartment
214 generally positioned above at least one and typically a row 132
of ice cube molds 126. Refill valve 110 is actuated when a belt
position sensor 133 (optical, mechanical, proximity switch or the
like) generates a signal to controller 116 indicating that belt 124
is in the correct position for refill. In one embodiment, belt
position sensor 133 detects holes that are punched though a band
that extends from the bottom web of conveyor belt 124 past a
sidewall of a respective ice cube mold 126. An IR LED positioned
adjacent, typically above, the band emits light that reaches a
photodiode positioned below the band only when a hole passes
between the two optical devices. An electronic circuit determines
whether the hole is present by processing the signal from the
photodiode. If the hole is between the LED and the photodiode, the
circuitry stops first motor 104 and commences a water dose.
[0035] Typically, refill valve 110 is positioned within a machine
or mechanical compartment (not shown). An inlet tubing 134 to
refill valve 110 enters fresh food compartment 214 from a rear wall
of the liner 220. A fill tube 136 connected to inlet tube 134
delivers water to a respective row 132 of ice cube molds 126 at a
portion of belt 124, typically adjacent to rear roller 122.
[0036] Second motor 106 (FIG. 2) can be positioned within fresh
food door 238 and is drivingly coupled to ice crusher 108, which
ice crusher 108 either crushes ice cubes 128 or delivers whole ice
cubes 128 depending on the user selection. An end user by means of
a push button 138, or similar actuation device selectively controls
second motor 106.
[0037] First motor 104 is energized when the fullness of ice cubes
128 in first ice cube storage bin 112 falls below a preset fill
level and an ice-ready sensor 142 generates a signal to controller
116 that a respective row 132 of ice cubes 128 to be delivered is
frozen. If a first fullness sensor 144 disposed within or about
first ice cube storage bin 112 generates a signal to controller 116
that the level of ice cubes 128 within first ice cube storage bin
112 has dropped below a preset fill level, a cycle is initiated and
first motor 104 advances conveyor belt 124 one full row 132 of ice
cube molds 126 and refill valve 110 delivers water to a row of
empty molds 126.
[0038] In one embodiment, ice-ready sensor 142 is a temperature
sensor such as a thermistor or a thermocouple in sliding contact
with belt 124 adjacent front roller 120 where ice cubes 128 are
delivered. Depending on the design of belt 124 and the airflow of
refrigerator 200 various algorithms can be used to determine ice
readiness from a temperature sensor. Time and temperature can be
integrated to provide a degree-minute set point beyond which it is
known that the ice is frozen. Alternatively a temperature cutoff
can be used below which it is known that the ice is frozen. This
temperature cutoff will typically be about 15 degrees
Fahrenheit.
[0039] Another ice-ready sensor 142 is based on capacitance. The
capacitance sensor is positioned below belt 124 near front roller
120. The sensor is part of a capacitance bridge circuit. An
excitation frequency is applied to the bridge. The bridge is
balanced such that when a respective ice cube mold 126 is empty the
voltage across the bridge is nearly zero. When water is in a
respective ice cube mold 126, the capacitance reading of ice-ready
sensor 142 increases dramatically, because the dielectric constant
of water is about 80 times that of air, causing the bridge to
become unbalanced. Thus the voltage signal sensed by controller 116
increases dramatically when water is in a respective ice cube mold
126. As the water freezes, the dielectric constant decreases to
about 6 times that of air, reducing the imbalance of the bridge and
decreasing the signal sent by ice-ready sensor 142 to controller
116. Alternatively, the bridge can be balanced such that the output
is nearly zero when water is present in the mold, in which case the
bridge becomes more unbalanced when the water freezes, and a large
output indicates that the ice is ready.
[0040] In operation, if a system user presses push button 138, a
signal is generated and controller 116 energizes second motor 106
and ice cubes 128 are delivered by auger mechanism 109 from first
ice cube storage bin 112 to a conventional ice dispenser. As with
most conventional delivery systems, a system user can select either
crushed ice or whole cubes to be delivered (or water in most
systems). If a user selects crushed ice, ice cubes 128 are fed from
first ice cube storage bin 112 to crusher 108. Second motor 106
activates crusher 108 and sets of rotating and stationary blades
break up the cubes as the blades pass each other, and the crushed
ice is delivered to the system user. If a user selects whole ice
cubes, crusher 108 is bypassed, via chute 148 and path selector
149, and whole ice cubes 128 are delivered to the system user.
[0041] Ice cubes 128 tend to stick tightly to most materials, and
in their hard-frozen state, they lend substantial rigidity to any
mold they may be frozen to. This may make it difficult to eject ice
cubes 128 in a hard-frozen state. Ice cubes in automatic icemakers
are usually melted by a heating element so as to produce a thin
film of liquid water between the ice cubes and the molds. This film
makes it easy to dislodge the ice cubes from the molds.
[0042] In this embodiment, bases of ice cube molds 126 are affixed
to the conveyor belt 124 on rectangular regions that are rigid and
planar in the regions where sides of molds 126 contact belt 124,
and that are somewhat flexible in the region of center of mold 126.
The regions of belt 124 between these rectangular regions are
flexible. The molds are not connected to belt 124 at any other
place except the bases. Thus, when rows of molds 126 pass around
front roller 120, a generally wedged shape region opens up between
adjacent rows due to the fact that the tops of the molds are at a
larger radius with respect to the roller shaft than the bases. Due
to the rigidity and the planarity of the regions where the sides of
the bases are attached to belt 124 and the flexibility of belt 124
between these regions, base regions in adjacent rows will naturally
want to follow a polygonal shape rather than a circle, and in a
preferred embodiment, such a shape is formed into the roller in the
regions where the bases are rigid and the belt tension is adjusted
to assure a tight fit between the polygon shape of the belt and
that in the roller.
[0043] In this same embodiment, the region of the roller that
contacts the central region of the molds is left in its original
cylindrical form. In this embodiment, there are circumferential
ridges disposed on roller 120 in the regions beneath centers of
molds 126. In both embodiments, the roller regions beneath centers
of molds 126 have a larger radius than the radius at which mold
centers would travel in an unstrained condition, and they must
deform in order to travel around the roller. This deformation will
break the bond between ice cubes 128 and mold 126 and eject the ice
cubes 128.
[0044] It should be noted that in order to fracture the bond
between the ice cube and its mold, shear must be propagated all the
way up the sides of the mold. This will happen if the sides of the
mold are sufficiently rigid, but if they are too flexible the
deformation induced at the base may not propagate all the way to
the top. In this case a stiffener can be incorporated either within
the sides of the molds or along an outside surface. In one
embodiment (not shown) external stiffeners are used which also
serve to stiffen the edges of the bases of the molds (as discussed
above).
[0045] Referring now to FIGS. 3-6, a second exemplary icemaker
assembly 300 is displayed therein and disposed a within freezer
compartment 212. It is to be appreciated that the exemplary
icemaker 300 is for illustrative purposes only and is not limited
to the specific icemaker described hereinafter.
[0046] As will become evident below, ice maker 300, in accordance
with conventional ice makers includes a number of electromechanical
elements that manipulate a mold to shape ice as it freezes, a
mechanism to remove or release frozen ice from the mold, and a
primary ice bucket for storage of ice produced in the mold.
Periodically, the ice supply is replenished by ice maker 300 as ice
is removed from a freezer compartment ice bucket or primary ice
bucket 368. The storage capacity of the primary ice bucket 368
provides increased ice capacity and is generally sufficient for
bulk use of ice (i.e. ice bucket or cooler fill-up).
[0047] FIG. 5 displays a cross sectional view of the exemplary
independent second icemaker 300. The icemaker 300 includes a metal
mold 350 with a tray structure having a bottom wall 352, a front
wall 354, and a back wall 356. A plurality of partition walls 358
extend transversely across mold 350 to define cavities in which ice
pieces 360 are formed. Each partition wall 358 includes a recessed
upper edge portion 362 through which water flows successively
through each cavity to fill mold 350 with water.
[0048] A sheathed electrical resistance heating element 364 is
press-fit, staked, and/or clamped into bottom wall 352 of mold 350
and heats mold 350 when a harvest cycle is executed to slightly
melt ice pieces 360 and release them from the mold cavities. A
rotating rake 366 sweeps through mold 350 as ice is harvested and
ejects ice from mold 350 into the primary or second storage bin or
second ice bucket 368. Cyclical operation of heater 364 and rake
366 are effected by a controller 370 disposed on a forward end of
mold 350, and controller 370 also automatically provides for
refilling mold 350 with water for ice formation after ice is
harvested through actuation of a water valve (not shown in FIG. 5)
connected to a water source (not shown) and delivering water to
mold 350 through an inlet structure (not shown).
[0049] In order to sense a level of ice pieces 360 in storage bin
368, a controller actuates a cam-driven feeler arm 372 rotates
underneath icemaker 300 and out over storage bin 368 as ice is
formed. Feeler arm 372 is spring biased to an outward or "home"
position that is used to initiate an ice harvest cycle, and is
rotated inward and underneath icemaker by a cam slide mechanism
(not shown) as ice is harvested from icemaker mold 350 so that the
feeler arm does not obstruct ice from entering storage bin 368 and
to prevent accumulation of ice above the feeler arm. After ice is
harvested, the feeler arm is rotated outward from underneath
icemaker 300, and when ice obstructs the feeler arm and prevents
the feeler arm from reaching the home position, controller 370
discontinues harvesting because storage bin 368 is sufficiently
full. As ice is removed from storage bin 368, feeler arm 372
gradually moves to its home position, thereby indicating a need for
more ice and causing controller 370 to initiate formation and
harvesting of ice pieces 360.
[0050] Freezer door or drawer 236 and fresh food doors 238, 239
close access openings to freezer and fresh food compartments 212,
214, respectively. Each door 238, 239 can be mounted by a top hinge
250 and a bottom hinge 252 to rotate about its outer vertical edge
between an open position, as shown in FIG. 6, and a closed
position, as shown in FIG. 3 closing the associated storage
compartment. Freezer door 236 can be a drawer slidably disposed
below the fresh food compartment 214 and can include a plurality of
storage shelves (not shown). The fresh food compartment 214 can
include a plurality of storage shelves 242 and a sealing gasket
244.
[0051] Second ice cube storage bin 368 can be removably disposed
within freezer compartment 212. Second ice cube storage bin 368 can
be a primary ice storage bulk bin and the first ice cube storage
bin 112 can be a supplemental storage bin, or vice versa. Second
ice cube storage bin 368 can be disposed in a lower portion of
freezer compartment 212.
[0052] First ice cube storage bin 112 can be removed from the door
238, and as such, when removed, its space 260 within door 238 can
be used for storing other items. To prevent the ice maker assembly
100 from sending ice cubes 128 to first ice cube storage bin 112
when first ice cube storage bin 112 is not in place, a detection
sensor can be used. In one embodiment, detection sensor 144 is a
microswitch that is actuated by a special geometrical feature of
first ice cube storage bin 112, such as a pin or a tab.
Alternatively, detection sensor 144 could be an inductive proximity
sensor that detects a metal insert on first ice cube storage bin
112, or an optical sensor that detects a reflecting surface adhered
to first ice cube storage bin 112, or the like. In one embodiment,
fullness sensor 144 is a weight determining means such as a
microswitch. In another embodiment, fullness sensor 144 is an
ultrasonic level detector. In another embodiment, fullness sensor
144 comprises an ultrasonic transmitter (piezo driver,) an
ultrasonic receiver (piezo microphone), and an electronic circuit
capable of causing transmitter to emit a short burst (approximately
100 microseconds long) of ultrasound and capable of measuring the
time interval between short burst and a return echo received by
receiver. This time interval is proportional to the distance
between fullness sensor 144 and the top layer of ice cubes 128 and
is therefore a measure of the fullness of ice cube storage bin
112.
[0053] In still another embodiment, fullness sensor 144 comprises
an optical proximity switch that detects the fullness of ice cube
storage bin 112. The optical switch sends out light (usually IR)
and detects the reflected light intensity with a photodiode. High
intensity of reflected light indicates close proximity of ice or
fullness. Pulse width modulation of the IR signal can be used to
increase the sensitivity of the optical switch.
[0054] An exemplary control logic sequence including selective
activation/deactivation modes for icemaker assemblies 100, 300 can
be described as follows. A user can selectively activate/deactivate
icemakers 100 and/or 300, as necessary, to meet current ice usage
and future bulk ice demands. For example, if demand for ice is
high, then both icemakers 100, 300 can be activated to provide the
maximum available ice in storage bins 112, 368.
[0055] If ice demand is of the light usage order, then icemaker 100
can be active while icemaker 300 is inactive. Ice cube storage bin
368 can be removed, thereby deactivating icemaker 300 during these
periods of light ice usage. The space consumed by bin 368 can then
be used for additional storage of typical freezer items.
[0056] When demand for ice requires bulk amounts, bin 368 can be
place into service and icemaker 300 reactivated. Bulk demands for
ice can arise when needed to fill, for example, an ice bucket or
cooler when preparing for a party or travel. It is to be
appreciated that if light ice usage is not a concern, but rather
having a moderate bulk supply of ice available (i.e. icemaker 300),
then ice bin 112 can be removed thereby deactivating icemaker 100.
The space consumed by bin 112 can then be used for additional
storage of typical fresh food items.
[0057] If there is no demand for ice, ice bins 112, 368 can both be
removed thereby deactivating both icemakers 100, 300. The space
consumed by bins 112, 368 can then be used for additional storage
of typical fresh food and frozen items, respectively.
[0058] As described above, when bins 112, 368 are in service,
fullness sensors 144, 372 will be monitoring the respective
fullness of the bins. If the signals generated from the fullness
sensors 144, 372 are greater than or equal to the preset fullness
value, icemakers 100, 300 will be idled. If, however, the signals
generated from fullness sensors 144, 372 are less than the preset
value (indicating low ice), the icemakers will be activated and
additional ice will be harvested.
[0059] It is to be appreciated that icemakers 100, 300, and the
associated mounting arrangements, can alternatively be mounted in
the freezer compartment and fresh food compartment, respectively.
In addition, the freezer and fresh food compartments can
respectively include identical icemakers, for example dual
icemakers 100 or dual icemakers 300, or other icemakers
conventionally known, albeit with each icemaker having the same or
different ice making production levels or capacities.
[0060] While the disclosure has been described with reference to
preferred embodiments, it will be understood by those skilled in
the art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the disclosure. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
disclosure without departing from the essential scope thereof.
Therefore, it is intended that the disclosure not be limited to the
particular embodiments disclosed herein, but that the disclosure
will include all embodiments falling within the scope of the
appended claims.
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