U.S. patent application number 12/708073 was filed with the patent office on 2010-06-10 for refrigerator and full ice level sensing apparatus thereof.
Invention is credited to Kyung-Han Jeong, Yong-Su Kim, Dong-Hoon LEE, Tae-Hee Lee, Kwang-Ha Suh.
Application Number | 20100139299 12/708073 |
Document ID | / |
Family ID | 42229547 |
Filed Date | 2010-06-10 |
United States Patent
Application |
20100139299 |
Kind Code |
A1 |
LEE; Dong-Hoon ; et
al. |
June 10, 2010 |
REFRIGERATOR AND FULL ICE LEVEL SENSING APPARATUS THEREOF
Abstract
A refrigerator and an ice level sensing apparatus are provided.
The refrigerator may include a main body, and an ice level sensing
apparatus including an optical element for sending or receiving a
signal, and an alignment device for aligning and maintaining
alignment of the optical element in a preset direction. The sensing
apparatus may sense whether an ice storage container in which ice
cubes made by an ice maker is at a full ice level. The optical
element may be aligned at a preset position, thus preventing
movement of the optical element, resulting in improved reliability
of the sensing apparatus.
Inventors: |
LEE; Dong-Hoon; (Seoul,
KR) ; Lee; Tae-Hee; (Seoul, KR) ; Kim;
Yong-Su; (Seoul, KR) ; Jeong; Kyung-Han;
(Seoul, KR) ; Suh; Kwang-Ha; (Seoul, KR) |
Correspondence
Address: |
KED & ASSOCIATES, LLP
P.O. Box 221200
Chantilly
VA
20153-1200
US
|
Family ID: |
42229547 |
Appl. No.: |
12/708073 |
Filed: |
February 18, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12423118 |
Apr 14, 2009 |
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12708073 |
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12423170 |
Apr 14, 2009 |
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12423118 |
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12423256 |
Apr 14, 2009 |
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12423170 |
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12433944 |
May 1, 2009 |
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12423256 |
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12470615 |
May 22, 2009 |
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12433944 |
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12471048 |
May 22, 2009 |
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12470615 |
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Current U.S.
Class: |
62/137 ; 62/344;
62/449 |
Current CPC
Class: |
G01F 23/2921 20130101;
F25C 5/187 20130101 |
Class at
Publication: |
62/137 ; 62/344;
62/449 |
International
Class: |
F25C 1/00 20060101
F25C001/00; F25C 5/18 20060101 F25C005/18; F25D 23/02 20060101
F25D023/02 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 15, 2008 |
KR |
10-2008-0034854 |
Apr 15, 2008 |
KR |
10-2008-0034856 |
Apr 15, 2008 |
KR |
10-2008-0034862 |
May 1, 2008 |
KR |
10-2008-0041084 |
May 27, 2008 |
KR |
10-2008-0049345 |
May 27, 2008 |
KR |
10-2008-0049346 |
Feb 19, 2009 |
KR |
10-2009-0014067 |
Claims
1. A refrigerator, comprising: a main body; a door coupled to the
main body; an ice maker installed in the main body or the door; a
storage container configured to receive and store the ice cubes
made by the ice maker; and a sensing apparatus configured to sense
an ice level in the storage container, the sensing apparatus
comprising: an optical element that sends or receives a signal; and
at least one alignment device that aligns and secures the optical
element in a preset direction.
2. The refrigerator of claim 1, wherein the optical element
comprises: a transmitting module that sends a signal; and a
receiving module that receives the signal sent by the transmitting
module.
3. The refrigerator of claim 1, wherein the sensing apparatus is
disposed at the ice maker.
4. The refrigerator of claim 2, wherein the transmitting module and
the receiving module are coupled to first and second printed
circuit boards (PCBs), respectively, and wherein the at least one
alignment device comprises first and second alignment devices that
couple the transmitting and receiving modules to the first and
second PCBs, respectively.
5. The refrigerator of claim 4, wherein each of the alignment
devices comprises: an accommodation portion in which a respective
transmitting or receiving module is accommodated; and a coupling
portion formed at one end of the accommodation portion so as to
couple the accommodation portion to the corresponding PCB.
6. The refrigerator of claim 5, wherein the coupling portion
comprises a plurality of coupling protrusions.
7. The refrigerator of claim 6, wherein each of the coupling
protrusions comprises a stopper configured to contact the
corresponding PCB so as to prevent the separation of the plurality
of coupling protrusions from the corresponding PCB.
8. The refrigerator of claim 6, wherein each of the coupling
protrusions is elastically deformable.
9. The refrigerator of claim 2, wherein the transmitting module
comprises a single transmitter and the receiving module comprises a
plurality of receivers.
10. The refrigerator of claim 9, wherein the single transmitter is
positioned on a first side of the ice maker and the plurality of
receivers are positioned on a second side of the ice maker opposite
the first side, and wherein the plurality of receivers are spaced
apart from each other on the second side of the ice maker so as to
form a receiving range in which the signal from the single
transmitter is received.
11. The refrigerator of claim 1, wherein the sensing apparatus
further comprises a temperature regulator configured to increase a
temperature of the optical element.
12. The refrigerator of claim 11, wherein the temperature regulator
comprises a heater configured to increase the temperature of the
optical element.
13. The refrigerator of claim 11, wherein the sensing apparatus
further comprises case in which the optical element and the at
least one alignment device are received, and a cover that covers
and open face of the case, the cover having a transparent
window.
14. The refrigerator of claim 13, wherein the temperature regulator
is positioned adjacent to the cover.
15. An ice level sensing apparatus for a refrigerator that senses
whether a storage container that stores ice cubes made by an ice
maker is fully filled with ice cubes, the apparatus comprising: a
case having an accommodation space formed therein; a printed
circuit board (PCB) received in the accommodation space; an optical
element mounted at the PCB and configured to send or receive a
signal; and an alignment device configured to align and maintain
alignment of the optical element in a preset direction.
16. The apparatus of claim 15, wherein the case is provided with an
opening through which the PCB is positioned in the accommodation
space, and wherein the apparatus further comprises a sealing cap
that covers and seals the opening.
17. The apparatus of claim 15, further comprising a heater
configured to increase a temperature of the optical element.
18. The apparatus of claim 17, wherein the case includes a
transparent window, and the heater is positioned at one side of the
transparent window.
19. An ice level sensing apparatus for a refrigerator, the sensing
apparatus comprising a transmitter and a receiver spaced apart from
each other, each having a case with an accommodation space formed
therein and a printed circuit board (PCB) disposed in the case,
wherein the sensing apparatus senses whether a container storing
ice cubes made by an ice maker is fully filled with ice cubes,
wherein the transmitter comprises a first electronic element
mounted at a corresponding PCB thereof, and a first alignment
device that aligns and secures the first electronic element in a
first preset direction, and wherein the receiver comprises a second
electronic element mounted at a corresponding PCB thereof, and a
second alignment device that aligns and secures the second
electronic element in a second preset direction.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Pursuant to 35 U.S.C. .sctn.119(a), this application claims
the benefit of an earlier filing date and right of priority to
Korean Application No. 10-2009-0014067, filed in Korea on Feb. 19,
2009, and is a Continuation-In-Part application of U.S. application
Ser. Nos. 12/423,118 filed Apr. 14, 2009, 12/423,170 filed Apr. 14,
2009, 12/423,256 filed Apr. 14, 2009, 12/433,944 filed May 1, 2009,
12/470,615 filed May 22, 2009 and 12/471,048 filed May 22, 2009,
respectively claiming priority to Korean Applications Nos.
10-2008-0034854 filed in Korea on Apr. 15, 2008, 10-2008-0034856
filed in Korea on Apr. 15, 2008, 10-2008-0034862 filed in Korea on
Apr. 15, 2008, 10-2008-0041084 filed in Korea on May 1, 2008,
10-2008-0049345 filed in Korea on May 27, 2008 and 10-2008-0049346
filed in Korea on May 27, 2008, the entirety of which is
incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] This disclosure relates to an ice level sensing apparatus
for a refrigerator.
[0004] 2. Background
[0005] A refrigerator refrigerates or freezes food items or the
like to keep them fresh in storage. The refrigerator includes an
ice maker for making ice and an ice container to receive ice made
by the ice maker.
[0006] A full ice detection lever, a mechanical device, coupled to
a controller detects whether or not the ice container is full of
ice. The full ice detection lever positioned at a lower side and
rises as high as the ice is accumulated in the ice container. When
the full ice detection lever rises by more than a certain height
due to ice accumulation, the controller determines that the ice
container is full. However, in the related art, if the full ice
detection lever becomes frozen, the mechanical operation of the
full ice detection lever is not likely to be performed, and the
controller cannot determine whether the ice container is full. In
such faulty state, ice is continuously supplied, causing an
overflow of ice from the ice container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The embodiments will be described in detail with reference
to the following drawings in which like reference numerals refer to
like elements wherein:
[0008] FIG. 1 is a perspective view of a refrigerator in accordance
with an embodiment as broadly described herein;
[0009] FIG. 2 is an enlarged perspective view of an ice maker and a
full ice level sensing apparatus of the refrigerator shown FIG.
1;
[0010] FIG. 3 is a sectional view of the ice maker shown in FIG.
2;
[0011] FIG. 4 is an enlarged view area A of FIG. 3;
[0012] FIG. 5 is a disassembled perspective view of the full ice
level sensing apparatus shown in FIG. 2;
[0013] FIG. 6 is an enlarged sectional view taken along the line
VI-VI of FIG. 2;
[0014] FIG. 7 illustrates a full ice level sensing operation using
the full ice level sensing apparatus of FIG. 2;
[0015] FIG. 8 is a block diagram of the ice maker of the
refrigerator shown in FIG. 1; and
[0016] FIG. 9 is a disassembled perspective view of a full ice
level sensing apparatus in accordance with another embodiment as
broadly described herein.
DETAILED DESCRIPTION
[0017] As shown in FIG. 1, a refrigerator as embodied and broadly
described herein may include a main body 110, doors 125 and 135, an
ice maker 150 provided with the main body 110 or one of the doors
125 or 135, an ice bin or container 180 for storing the ice cubes
made by the ice maker 150, an ice level sensing apparatus 220
provided with sensor elements 240 for sending or receiving a signal
and an alignment device 250 for aligning and maintaining alignment
of the sensor element 240 in a preset direction.
[0018] A freezing chamber 120 and a refrigerating chamber 130 for
keeping food items in a frozen fresh state may be formed in the
main body 110. The main body 110 may be a side by side type having
the freezing chamber 120 and the refrigerating chamber 130 disposed
next to each other in a horizontal direction. Alternatively, the
main body 110 may be a top freezer or bottom freezer type having
the freezing chamber 120 and the refrigerating chamber 130 one on
top of the other disposed in a vertical direction.
[0019] The main body 110 may be provided with a refrigerating cycle
device (not shown in detail) for providing cool air into the
freezing chamber 120 and the refrigerating chamber 130. The
refrigeration cycle device may employ a vapor compression type
refrigerating cycle in which cool air is generated via a series of
processes of compressing, condensing, expanding and evaporating a
refrigerant.
[0020] The freezing chamber door 125 and the refrigerating chamber
door 135 for opening and closing the freezing chamber 120 and the
refrigerating chamber 130 may be rotatably coupled to front
surfaces of the freezing chamber 120 and the refrigerating chamber
130, respectively. In the embodiment shown in FIG. 1, which is,
simply for ease of discussion, a side by side type, the ice maker
150 for making ice cubes may be disposed at the freezing chamber
door 125. In alternative embodiments, the ice maker 150 may be
disposed within the main body 110. In other alternative
embodiments, the ice maker 150 may be installed at an ice making
chamber formed in a refrigerating chamber door (not shown). In any
of these embodiments, the ice bin or container 180 for storing ice
cubes made by the ice maker 150 may be positioned below the ice
maker 150.
[0021] The ice maker 150 or the ice bin or container 180 may be
provided with an ice level sensing apparatus 220 for sensing
whether the ice bin or container 180 is at the full ice level. In
this embodiment, an example in which the ice level sensing
apparatus 220 is disposed at the ice maker 150 will be described. A
dispenser 210 that dispenses ice cubes stored in the ice bin or
container 180 to the outside may be disposed below the ice bin or
container 180.
[0022] As shown in FIGS. 2 and 3, the ice maker 150 may include an
ice tray 151 having a plurality of cells in which water is supplied
to make ice cubes having a designated shape, a water supply 155 for
supplying water into the ice tray 151, an ejector 161 for ejecting
the ice cubes from the ice tray 151, a slider 167 oriented at an
incline to guide the ice cubes ejected by the ejector 161, an ice
separation heater for heating up the ice tray 151 to separate the
ice cube made in each cell from the cell, a driver for driving the
ejector 161, and a control box 170 for accommodating a controller
which controls the driver and the ice separation heater.
[0023] The ejector 161 may include a shaft 163, and a plurality of
ejector pins 165 that protrude radially from the shaft 163 and are
spaced apart from one another in an axial direction along the
length of the shaft 163. The ejector pins 165 may be aligned with
the corresponding cells partitioned in the ice tray 151 so that,
upon the rotation of the ejector 161, each of the ejector pins 165
rotates to apply pressure to and separate the ice cube from the
corresponding cell, allowing the ice cube to be dropped out of the
cell. A holder 175 for accommodating the ice separation heater
therein may be disposed below the ice making tray 151.
[0024] The ice bin or container 180 may include a body 181 having
an accommodation space therein. The body 181 may have an ice outlet
182 formed at its lower portion, a transfer screw (or auger) 183
rotatably disposed at a lower portion of the inside of the body
181, and an ice breaker 191 for breaking/crushing ice. The transfer
screw 183 may be formed in a helical shape so as to direct ice
towards the ice breaker 191.
[0025] The ice breaker 191 may include a plurality of fixed blades
193 fixed to the inside of the body 181, and a plurality of movable
blades 195 that rotate relative to the fixed blades 193.
Accordingly, ice cubes placed between the fixed blades 193 and the
movable blades 195 are broken/crushed. A transfer screw driving
motor 185 for rotating the transfer screw 183 may be disposed at
one end portion of a shaft of the transfer screw 183.
[0026] An ice passage 212 that guides the ice downwardly may be
formed at a lower side of the ice outlet 182 of the ice bin or
container 180. The ice passage 212 may be connected to the
dispenser 210. The ice passage 212 may be provided with a switching
mechanism (not shown) for opening and closing the ice passage
212.
[0027] Various types of ice makers and operations thereof are
disclosed in U.S. Pat. Nos. 7,210,299, 7,080,518, 7,017,354,
6,857,279, and 6,705,091, whose entire disclosures are incorporated
herein by reference. These patents are also commonly assigned to
the same assignee of this application.
[0028] With reference to FIGS. 2, 4 and 6, a transmitting unit or
module 220a is installed in a sensor housing or case 221, and a
receiving unit or module 220b is installed in a housing or case 221
at a portion extending from the holder 175 to correspond to the
sensor case 221 of the transmitting unit or module 220a. A
transmitter 240a and one or more receivers 240b for transmitting
and receiving signals may be installed in the transmitting unit or
module 220a and the receiving unit or module 220b, respectively, to
face each other. Based on the transmitted and received signals, the
transmitting unit or module 220a and the receiving unit or module
220b are used to detect an ice-full state of the ice container 180.
The ice level sensing apparatus 220 comprises at least one of the
transmitter 240a and the one or more of the receivers 240b, and may
further include transmitting and receiving units or modules 220a,
220b, and sensor housings 221, and is used to determine or detect
ice full state of the ice container 180.
[0029] The sensing apparatus 120 may be disposed in or near the
top, above or below the top of the ice container 180 at a position
corresponding to the height at which ice is fully accumulated or
collected. The transmitter and/or receiver may be optical devices
to transmit or receive IR light. For example, the transmitter or
emitter may be an IR photo diode and the receiver may be a photo
transistor. The structure of the optical emitter or receiver is
disclosed in U.S. Pat. No. 4,201,910, whose entire disclosure is
incorporated herein by reference.
[0030] As shown in FIGS. 3 and 4, the receiving unit or module 220b
of the sensing apparatus 220 may extend in a downward direction
down to the interior of the ice storage container 180. The
receivers 240b may be disposed at a position corresponding to the
height of the ice-full state of the ice container 180. Although,
the position of the receivers 240b have been described, the
transmitting unit or module 220a and the transmitter 240a may be
formed to correspond to or near the height of the receiving unit or
module 220b and the receivers 240b, as can be appreciated by one of
ordinary skill in the art. In this embodiment, a detection height
of the sensing apparatus 220 may have a certain height difference
from an upper end or top ridgeline of the ice container 180.
[0031] The transmitting unit or module 220a and the receiving unit
or module 220b of the sensing apparatus 220 are located at both
sides of an ice discharging outlet, a passage through which ice is
discharged from the ice maker. The receiver 240b receives infrared
rays transmitted from the transmitter 240a, traversing the ice
discharging outlet, and provide corresponding signals for
determining whether the ice container 180 is substantially full of
ice to detect the ice-full state. As can be appreciated, the
location of the transmitting unit or module 220a and the receiving
unit or module 220b may be reversed, i.e., receiver on the right
and transmitter on the left.
[0032] In this embodiment, the transmitting unit or module 220a and
the receiving unit or module 220b are separated by a prescribed
distance which is less than a width of the ice container 180. Such
lesser distance to the width allows the modules to be placed within
the ice container 180. In an alternative embodiment, the distance
may be greater than the width such that the modules may be located
outside the ice container 180, which may have a cut-out to allow
passage of the light or may be made of transparent material.
[0033] More specifically, the cases 221 of the ice level sensing
apparatus 220 may include may each an accommodation space therein,
with printed circuit boards (PCBs) 231 each accommodated in a
corresponding case 221, and sensing (or optical) elements 240
(transmitters or receivers) for sending or receiving a signal
provided on the PCBs 231, and alignment devices 250 for aligning
and maintaining alignment of the sensing/optical elements 240 in a
preset direction. Each sensing/optical element 240 may include the
transmitter 240a for sending a signal, and one or more receivers
240b for receiving a signal, as described above.
[0034] The transmitter 220a and the receiver 220b may be spaced
apart from each other by a preset distance. Alternatively, the
transmitter 220a and the receiver 220b may be configured as a
reflective sensing device, which is accommodated in the same case
221 and configured such that a signal, sent from the transmitter
220a and then reflected on a target (in this embodiment, the target
being an ice cube placed at a position of a full ice level) is
received at the receiver 220b.
[0035] Each case 221 may be formed integrally with the holder 175,
so as to facilitate the connection with the ice maker 150, and the
alignment between the transmitting unit or module 240a and the
receiving unit or module 240b. Alternatively, each case 221 may be
independently formed so as to be coupled to the holder 175. Also,
the case 221 may be coupled to the ice bin or container 180. In
certain embodiments, the case 221 may be positioned at a periphery
of the ice bin or container 180 and then the ice bin or container
180 may be provided with a signal passing portion (e.g., a hole, a
transparent window, etc.) through which a signal from the
transmitting unit or module 240a may be sent.
[0036] The transmitter 220a of the sensing apparatus 220 may be
provided with one of the PCBs 231, the transmitter 240a of the
electronic/optical element 240, and one of the alignment devices
250. The receiver 220b of the sensing apparatus 220 may be provided
with the other of the PCBs 231, the one or more receivers 240b of
the electronic/optical element 240, and the other alignment device
250. Accordingly, movement of the electronic/optical element 240,
in more detail, the transmitter 240a and the receiver 240b, may be
avoided, thereby improving reliability of the sensing function of
the ice level sensing apparatus 220.
[0037] In certain embodiments, the transmitter 240a and the
receiver 240b may be, for example, infrared sensors using infrared
rays as signals. The transmitter 240a may be a single component,
and the receiver 240b may include a plurality of components. In
this embodiment, two receivers 240b are spaced apart from each
other. Accordingly, the signal sent from the single transmitter
240a may be received at either of the two receivers 240b, thereby
forming a wider sensing area, resulting in further improvement in
reliability of the sensing operation.
[0038] In certain embodiments, transmitter 240a may output a pulse
type signal at a designated interval. The receivers 240b may be
configured to output the number of received signals, or pulses,
received from the transmitter 240a as a signal having a preset
voltage (level).
[0039] The transmitter 240a and the receiver 240b may be spaced
apart from each other at a preset distance, and may be positioned
at the full ice level within the ice bin or container 180. If the
number of signals, or pulses, received by the receivers 240b is
greater than a set value, it is determined that the inside of the
ice bin or container 180 is not at the full ice level. If the
number of signals received is less than the set value, it is
determined that the ice bin or container 180 is at the full ice
level.
[0040] In more detail, as shown in FIG. 7, if ice is filled in the
ice bin or container 180 up to the full ice level, a signal, or
light, sent from the transmitter 240a is blocked from reaching the
receivers 240b, or is reflected by the ice cubes, and thus the
receivers 240b cannot receive the signal from the transmitters
240a. The receivers 240b may be positioned vertically spaced apart
from each other. Alternatively, the receivers 240b may be
horizontally spaced apart from each other.
[0041] Each alignment device 250 may be coupled to the
corresponding PCB 231, which simplifies the configuration and
facilitates fabrication and assembly, thereby reducing fabricating
cost. Each PCB 231 may be provided with a circuit that allows the
electronic/optical element 240 to send or receive a signal. Each of
the alignment devices 250 may include an accommodation portion 251
in which the electronic/optical element 240 is received and
coupled, and a coupling portion 255 formed at one end of the
accommodation portion 251 which may be coupled to the corresponding
PCB 231.
[0042] Each of the electronic/optical elements 240 (i.e., 240a and
240b) may be provided with a main body 241 having a substantially
circular section, and a plurality of lead lines 243 extending from
one side of the main body 241 to be mounted at the PCB 231. A
protrusion 242 may extend outwardly from one end portion of the
main body 241. A through hole 253 may be formed at the
corresponding accommodation portion 251, at a position
corresponding to the protrusion 242 so as to allow one end of the
main body 241 to protrude outwardly. An accommodation space 254 may
be formed within the accommodation portion 251 so as to accommodate
the area of the protrusion 242.
[0043] The connection portion 255 may be provided with a plurality
of coupling protrusions 257 coupled to the PCB 231. The coupling
protrusions 257 may each extend from an end portion of the
accommodation portion 251 in a lengthwise direction and may be
spaced apart from one another in a circumferential direction. For
example, the embodiment shown in FIGS. 5 and 6 employs four
coupling protrusions 257. The coupling protrusions 257 may be
elastically deformable to allow the coupled state with the PCB 231
to be firmly maintained. A stopper 258 may be formed at an end
portion of each coupling protrusion 257 to prevent sudden
separation of the coupling protrusion 257 after it is coupled to
the PCB 231. A slanted guiding surface 259 may be formed at one
side of each stopper 258.
[0044] Corresponding to this configuration, the PCB 231 may be
provided with insertion holes 233 formed therethrough such that the
coupling protrusions 257 may be inserted therein and coupled to the
PCB 231. Each insertion hole 233 may extend inwardly through the
PCB 231 and be sized such that the corresponding coupling
protrusion 257 may be inserted in the insertion hole 233 and be
elastically deformed. Accordingly, upon inserting the coupling
protrusions 257, the guiding surface 259 comes in contact with the
insertion hole 233, deforming the coupling protrusion 257 and
allowing the coupling protrusion 257 to slide through the insertion
hole 233. After it extends all the way through to the opposite side
of the PCB 231, the coupling protrusion 257 is restored to its
original state by its own elastic force, so as to elastically come
in contact with an inner surface of the insertion hole 233. The
stopper 258 is stopped at an outer edge of the insertion hole 233,
thereby preventing the coupling protrusion 257 from being
unexpectedly separated from the insertion hole 233.
[0045] Each of the cases 221 may be provided with an accommodation
space 223 having one side open. A cover 225 may be disposed at the
open side of the case 221. A sealing member 227 may be disposed
between the case 221 and the cover 225. The sealing member 227 may
be formed of an elastic material (e.g., rubber, silicon, or the
like) with elasticity. The sealing member 227 may prevent external
moisture from entering into the accommodation space 223 through a
space between the case 221 and the cover 225, preventing damage to
the electronic element 240 due to freezing of moisture.
[0046] Each of the covers 225 may be provided with a transparent
window through which a signal from the transmitter 240a may be sent
and received by the receiver 240b. In certain embodiments, the
entire cover 225 may be made of a transparent material, and thus
the cover 225 may also serve the function of the transparent
window. Alternatively, a part of the cover 225, i.e., an area
corresponding to the front surface of the electronic/optical
element 240, may be configured as the transparent window.
[0047] The case 221 or the cover 225 may be provided with a
temperature rising portion 261, or heater, for increasing the
temperatures of the electronic/optical element 240 and the cover
225 (substantially, at least the transparent window of the cover
225) to prevent frosting. Hence, signal degradation (e.g.,
interference, distortion, and the like) due to frosting may be
prevented, resulting in improvement of sensing reliability.
[0048] The temperature rising portion 261, or heater, may be, for
example, an electric heater or a plate-type heater with a
relatively thin thickness (e.g., in the form of a film or sheet,
and may operate by receiving power applied every time the main body
110 operates. The temperature rising portion 261 may have a thermal
value great enough to prevent frosting on the electronic element
240 and the cover 225 (transparent window). In certain embodiments,
the temperature rising portion 261 may be supported by a supporting
portion 228 provided at the rear surface of the cover 225, as shown
in FIG. 6.
[0049] As shown in FIG. 8, the refrigerator in accordance with this
embodiment as broadly described herein may include a controller 265
implemented as, for example, a microprocessor having a control
program for controlling the ice making process. The ice level
sensing apparatus 220, which senses whether the ice bin or
container 180 is at the full ice level so as to control the ice
making process of the ice maker 150, a driver 267 and an ice
separation device 269, such as, for example, a heater, may be
connected to the controller 245 so that the controller 265 can
control these components. In more detail, the PCB 231 to which the
transmitter 240a of the ice level sensing apparatus 220 is
connected, the PCB 231 to which the plurality of receivers 240b are
connected, and the temperature rising portion (i.e., heater) 261
may all be connected to the controller 265.
[0050] During operation, water is supplied into the ice tray 151
via the water supply 155. After a preset period of time (i.e., a
time required for freezing the water) elapses, the controller 265
determines whether the ice bin or container 180 is at the full ice
level based upon a sensing signal from the ice level sensing
apparatus 220. If it is determined that the ice bin or container
180 is not at the full ice level, the controller 265 then applies
power to the ice separation device 269 to separate ice from the ice
tray 151 and deposit it into the ice bin or container 180, and
continue the ice making process.
[0051] When power is applied to the ice separation device 269,
outer surfaces of the ice cubes within the ice tray 151 are
slightly melted by the ice separation heater and thus the ice cubes
are separated from the ice tray 151. The controller 265 controls
the driver 267 such that the ejector 161 can rotate in order to
eject the separated ice cubes and store them in the ice bin or
container 180. When the ejector 161 rotates, the separated ice
cubes from the ice tray 151 are pushed upwardly by the ejector pins
165 and dropped down into the ice bin or container 180 along the
upper surface of the slider 167.
[0052] Meanwhile, if the ice level sensing apparatus 220 senses
that the ice bin or container 180 is at the full ice level, then
the controller 265 stops the operation of the ice separation device
269 and the driver 267 and suspends the ice making process.
[0053] Hereinafter, an ice level sensing apparatus for a
refrigerator in accordance with another embodiment as broadly
described herein will be discussed with reference to FIG. 9.
[0054] As shown in FIG. 9, an ice level sensing apparatus 320 may
include cases 321 each forming an accommodation space therein,
printed circuit boards (PCB) 331 each accommodated in a
corresponding case 321, an electronic/optical element 240 for
sending or receiving a signal disposed at the PCB 331, and
alignment devices 250 for aligning and maintaining alignment of the
electronic elements 240 towards a preset direction. Each
electronic/optical element 240 may include a transmitter 240a for
sending a signal, and a receiver 240b for receiving a signal sent
from the transmitter 240a. The transmitter 240a and the receiver
240b may be infrared sensors for sending and receiving infrared
signals.
[0055] The transmitter 240a and the receiver 240b may be coupled to
separate PCBs 331 by separate alignment devices 250 and then
accommodated in the separate cases 321. Alternatively, the
transmitter 240a and the receiver 240b may be aligned at a single
PCB 331 by separate alignment units 250 and accommodated in a
single case 321.
[0056] Hereinafter, for purposes of discussion, it will be assumed
that the transmitter 240a and the receiver 240b are aligned at the
separate PCBs 331 by separate alignment devices 250 and
accommodated in separate cases 321. The detailed description of the
ice level sensing apparatus having the transmitter 240a may be
understood by the aforementioned embodiment, and hereinafter, the
ice level sensing apparatus having the receivers 240b as shown in
FIG. 9 will be described.
[0057] As shown in FIG. 9, two electronic/optical elements 240 are
provided on one PCB 331. The electronic/optical element 240, as
described above, may include the receivers 240b for receiving a
signal from the transmitter 240a. Accordingly, a sensing area for
one signal may be extended so as to improve sensing
reliability.
[0058] The two electronic/optical elements 240 are spaced apart
from each other on the PCB 331. Insertion holes 333, to which the
alignment devices 250 are coupled, may be formed through the PCB
331 corresponding to the peripheries of the electronic/optical
elements 240.
[0059] Each of the alignment devices 250 may be provided with an
accommodation portion 251 in which the corresponding
electronic/optical element 240 is accommodated, and a coupling
portion 255 for coupling the accommodation portion 251 to the PCB
331.
[0060] The coupling portion 255 may include a plurality of coupling
protrusions 257 which are elastically deformable. Each of the
coupling protrusions 257 may have a stopper 258 and a guiding
surface 259 that is inclined in an insertion direction at one end
of the stopper 258.
[0061] The case 321 may have an upwardly open accommodation space.
A transparent window 323, through which a signal sent from the
transmitter 240a may be sent/received, may be formed at one side of
each case 321.
[0062] Guide slots 324 for guiding the accommodation and alignment
of the PCB 331 having the electronic/optical element 240 coupled
thereto may be formed in each case 321. Guide protrusions 325 may
be formed at two opposite side regions within the case 321 to
define the guide slots 324. The guide slots 324 may to be
positioned in the case 321 such that two opposite end portions of
the PCB 321 can be slidably inserted.
[0063] A coupling device 327 for coupling the corresponding case
321 to the ice maker 150 using, for example, a coupling member (not
shown) such as a screw, may be formed at one side of the case 321
such as, for example, an upper side of the case 321 in this
embodiment. Alternatively, a plurality of coupling devices 327 may
be provided at side portions of the case 321 to fix the case 321,
for example, to an inner side wall of the ice bin or container
180.
[0064] A sealing cap 333 for sealing the inside of the case 321
from the outside thereof may be disposed at an opened upper portion
of the case 321. Therefore, external moisture can be prevented from
entering the case 321, thereby avoiding an adverse effect due to
moisture.
[0065] The transparent window 323 may be formed at one side of the
case 321. At one region of the rear surface of the transparent
window 323, a temperature rising portion, i.e., an electric heater
261, may be provided to increase an internal temperature and
prevent the electronic/optical elements 240 and the transparent
window 323 from frosting. The heater 261 may generate heat upon
power being applied thereto and may be, for example a plate-type
heater.
[0066] When so configured, the end portion of the electronic
element 240 mounted at the PCB 331 is inserted in the alignment
unit 250, and also the end portion of each coupling protrusion 257
of the corresponding alignment device 250 is inserted in the
corresponding insertion hole 333 of the PCB 331. Each coupling
protrusion 257 is elastically deformed as the insertion hole 333
comes in contact with the inclined guiding surface 259, and then
restored to its initial position by its own elastic force after
being inserted through the insertion hole 333. Accordingly, the
alignment device 250 can be prevented from being unexpectedly
separated from the PCB 321.
[0067] Upon power being applied thereto, the heater 261 emits heat
to increase the temperature of the transparent window 323 and the
electronic/optical element 240, so as to prevent degradation in
signal sensitivity (e.g., damage, refraction, distortion, and the
like) due to the frosting of the electronic/optical element 240 and
the transparent window 323, thereby enhancing reliability of
sensing the ice level of ice cubes in the ice bin or container
180.
[0068] As described above, in accordance with one embodiment as
broadly described herein, by employing an alignment unit for
aligning an electronic/optical element in a preset direction and
maintaining the aligned state of the electronic element, the
electronic/optical element can be prevented from being loosened
(moved, shaken), and thus its reliability in sensing the ice full
level can be improved.
[0069] Also, the alignment device may have an accommodation portion
for accommodating the electronic/optical element and a coupling
portion for fixing a target to one side of the accommodation
portion, so as to allow for a simple configuration and facilitate
fabrication and assembly, resulting in improvement of sensing
reliability with low fabricating cost.
[0070] Also, a heater can further be provided for preventing the
frosting of the electronic element, so as to further improving the
sensing reliability.
[0071] A refrigerator is provided that is capable of enhancing
reliability of sensing as to whether ice cubes are fully filled in
an ice bin or container, and a full ice level sensing apparatus for
the refrigerator.
[0072] A refrigerator is provided that is capable of implementing a
simple configuration with low fabricating cost and enhancing
reliability of a sensing as to whether ice cubes are fully
contained, and a full ice level sensing apparatus therefor.
[0073] A refrigerator as embodied and broadly described herein may
include a refrigerator main body and a door; an ice maker disposed
at the refrigerator main body or the door and configured to make
ice cubes; an ice bin or container configured to store the ice
cubes made by the ice maker; and a full ice level sensing apparatus
provided with an electronic element unit for sending or receiving a
signal, and alignment units for aligning and maintaining the
electronic element unit in a preset direction, and configured to
sense whether the ice bin or container is fully filled with the ice
cubes.
[0074] The electronic element unit may include a sending portion
for sending a signal and a receiving portion for receiving the
signal.
[0075] The full ice level sensing apparatus may be disposed at the
ice maker.
[0076] The sending portion and the receiving portion may be mounted
at different printed circuit boards (PCBs), respectively, wherein
the alignment units are coupled to the corresponding PCBs.
[0077] Each of the alignment units may include an accommodation
portion in which the sending portion and the receiving portion are
accommodated, and a coupling portion formed at one side of the
accommodation portion and coupled to the corresponding PCB.
[0078] The coupling portion may include a plurality of coupling
protrusions.
[0079] Each of the coupling protrusions may include a stopper
configured to come in contact with the corresponding PCB to prevent
the coupling protrusion from being separated.
[0080] The coupling protrusion may be elastically
transformable.
[0081] The sending portion may be configured as a single part and
the receiving portion may be provided in plurality.
[0082] The full ice level sensing apparatus may further include a
temperature rising portion configured to rise the temperature of
the electronic element unit.
[0083] The full ice level sensing apparatus may further include
case and cover both for accommodating the electronic element unit
and the alignment unit, respectively, the cover having a
transparent window.
[0084] The temperature rising portion may be disposed at the
cover.
[0085] A full ice level sensing apparatus for a refrigerator as
embodied and broadly described herein may include a case forming an
accommodation space therein; a printed circuit board (PCB)
accommodated in the case; an electronic element unit configured to
send or receive a signal, and mounted at the PCB; and an alignment
unit configured to align and maintain the electronic element unit
in a preset direction.
[0086] The case may be provided with an opening through which the
PCB is accommodated, and the apparatus may further include a
sealing cap configured to seal the opening of the case.
[0087] The apparatus may further include a heater configured to
rise the temperature of the electronic element unit.
[0088] The case may be provided with a transparent window, and the
heater may be disposed at one side of the transparent window.
[0089] A full ice level sensing apparatus for a refrigerator as
embodied and broadly described herein may include sending unit and
receiving unit, spaced from each other, each having a case forming
an accommodation space therein, and a printed circuit board (PCB)
disposed in the case, for sensing whether an ice bin or container
storing ice cubes made by an ice maker is fully filled with the ice
cubes, wherein the sending unit comprises an electronic element
unit mounted at the PCB of the sending unit for sending a signal,
and an alignment unit for aligning and maintaining the electronic
element unit in a preset direction, wherein the receiving unit
comprises an electronic element unit mounted at the PCB of the
receiving unit for receiving a signal, and an alignment unit for
aligning and maintaining the electronic element unit in a preset
direction.
[0090] Any reference in this specification to "one embodiment," "an
embodiment," "example embodiment," etc., means that a particular
feature, structure, or characteristic described in connection with
the embodiment is included in at least one embodiment of the
invention. The appearances of such phrases in various places in the
specification are not necessarily all referring to the same
embodiment. Further, when a particular feature, structure, or
characteristic is described in connection with any embodiment, it
is submitted that it is within the purview of one skilled in the
art to effect such feature, structure, or characteristic in
connection with other ones of the embodiments.
[0091] Although embodiments have been described with reference to a
number of illustrative embodiments thereof, it should be understood
that numerous other modifications and embodiments can be devised by
those skilled in the art that will fall within the spirit and scope
of the principles of this disclosure. More particularly, numerous
variations and modifications are possible in the component parts
and/or arrangements of the subject combination arrangement within
the scope of the disclosure, the drawings and the appended claims.
In addition to variations and modifications in the component parts
and/or arrangements, alternative uses will also be apparent to
those skilled in the art.
* * * * *