U.S. patent application number 14/651180 was filed with the patent office on 2016-01-07 for icemaker.
The applicant listed for this patent is DAECHANG CO., LTD.. Invention is credited to Jun Dong JI, Kyong Su LEE.
Application Number | 20160003514 14/651180 |
Document ID | / |
Family ID | 54591569 |
Filed Date | 2016-01-07 |
United States Patent
Application |
20160003514 |
Kind Code |
A1 |
JI; Jun Dong ; et
al. |
January 7, 2016 |
ICEMAKER
Abstract
Disclosed is an icemaker. The icemaker in accordance with one
embodiment of the present invention comprises: an ice tray; at
least one heater housing portion which is formed on the ice tray;
and a heater, which is provided with a soft external cover or an
external cover having elastic force and is housed inside the heater
accommodation portion while being in close contact with the heater
accommodation portion, for heating the ice tray.
Inventors: |
JI; Jun Dong; (Gyeonggi-do,
KR) ; LEE; Kyong Su; (Gyeonggi-do, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DAECHANG CO., LTD. |
Jeollabuk-do |
|
KR |
|
|
Family ID: |
54591569 |
Appl. No.: |
14/651180 |
Filed: |
October 28, 2013 |
PCT Filed: |
October 28, 2013 |
PCT NO: |
PCT/KR2013/009639 |
371 Date: |
June 10, 2015 |
Current U.S.
Class: |
62/351 |
Current CPC
Class: |
F25C 5/08 20130101 |
International
Class: |
F25C 1/04 20060101
F25C001/04; F25C 5/02 20060101 F25C005/02 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 10, 2012 |
KR |
10-2012-0142886 |
Feb 13, 2013 |
KR |
10-2013-0015451 |
Feb 15, 2013 |
KR |
10-2013-0016318 |
Claims
1. An ice maker, comprising: an ice tray; at least one heater
housing formed in the ice tray; at least one heater to heat the ice
tray, the heater including an outer shell so as to be accommodated
in a close contact within the heater housing; and a base cover
coupled to the ice tray, the base cover including support ribs for
pressurizing the heater mounted in the heater housing to make the
heater getting in a close contact with the heater housing.
2. The ice maker of claim 1, wherein the heater is a cord
heater.
3. (canceled)
4. (canceled)
5. (canceled)
6. (canceled)
7. (canceled)
8. (canceled)
9. (canceled)
10. The ice maker of claim 1, wherein each of the support ribs
further includes a shield which is formed at the terminal of the
support rib to shield the inside of the heater housing.
11. The ice maker of claim 10, wherein the heater support is formed
by protruding from the shield, the heater support further
comprising a heater support protrusion which gets in a contact with
the heater.
12. (canceled)
13. The ice maker of claim 10, wherein the heater housing
comprises: a pair of protrusions which are formed by protruding
from the outer circumferential surface of the ice tray; and an
accommodating recess which is formed between the pair of
protrusions and allows the heater to be inserted, wherein the
shield is formed at the terminal of the support rib and gets in
contact with the pair of protrusions to radiate the heat
transferred from the heater through the pair of protrusions.
14. The ice maker of claim 1, further comprising a sealing member
which is filled within the heater accommodating recess to support
the heater, the heater accommodating recess composing the heater
housing.
15. The ice maker of claim 1, wherein the heater housing comprises:
a pair of protrusions formed by protruding from the outer
circumferential surface of the ice tray, any one of the pair of
protrusions being protruded with a length longer than that of the
other protrusion.
16. The ice maker of claim 15, wherein the heater housing is formed
in plurality on the outer circumferential surface of the ice tray
having a semi-cylindrical shape, and wherein a first protrusion of
the pair of protrusions adjacent to one side or the other side of
the ice tray is protruded with a length corresponding to a diameter
of the heater, and a second protrusion of the pair of protrusions
is protruded with a length longer than that of the first
protrusion.
17. The ice maker of claim 16, wherein the second protrusion of the
pair of protrusions is formed by protruding with a length less than
that of the first protrusion of the pair of protrusions of the
adjacent heater housing.
18. An ice maker, comprising: an ice tray; at least one heater
housing formed in the ice tray; at least one heater to heat the ice
tray, the heater including an outer shell so as to be accommodated
in a close contact within the heater housing; an overheating sensor
for detecting whether the heater is overheated, one side of the
overheating sensor being installed on a lead wire connected to the
heater; a base cover coupled to the ice tray to protect the heater;
and a sensor support unit provided in one side of the base cover,
the sensor support unit comprising a support member in which a
coupling portion is formed to be extended to the side surface of
the ice tray so as for the overheating sensor to get in a close
contact with the ice tray, wherein the base cover comprises support
ribs formed therein, the support ribs pressurizing the heater
mounted in the heater housing to make the heater in a close contact
with the heater housing.
19. The ice maker of claim 18, wherein the support member gets in a
close contact with the ice tray and is positioned between the ice
tray and a control box coupled to the ice tray.
20. The ice maker of claim 18, where the support member with the
coupling portion therein comprises at least one inserting hole
formed therein through which a lead wire passes.
21. The ice maker of claim 18, wherein the coupling portion of the
support member includes an inserting recess formed on the surface
opposing to the ice tray in the extended frame, and wherein the
overheating sensor is inserted into the inserting recess to get in
a close contact with the ice tray.
22. The ice maker of claim 21, wherein the support member includes
a through hole communicating with the coupling portion formed
thereon, so that the overheating sensor gets in a close contact
with the ice tray which is inserted into the coupling portion
through the through hole.
23. The ice maker of claim 18, wherein the heater is a flexible
heater, the heater including a molding portion which is formed on
the area of connection between the heater and the lead wire, and
wherein a molding housing is formed in the support member, the
molding housing accommodating the molding portion.
24. (canceled)
25. An ice maker, comprising: an ice tray; at least one heater
housing formed in the ice tray; and at least one heater to heat the
ice tray, the heater being including an outer shell so as to be
accommodated in a close contact within the heater housing, wherein
the heater comprises: a heating unit; a first insulating layer
formed by surrounding the heating unit, the first insulating layer
being made of a soft or an elastic material; and a second
insulating layer formed by surrounding the first insulating layer,
the second insulating layer being treated with a cross-linking
treatment.
26. (canceled)
27. The ice maker of claim 25, wherein the second insulating layer
is formed by an extruding process on the outer circumferential
surface of the first insulating layer.
28. The ice maker of claim 25, wherein the second insulating layer
is made of Ethylene Vinyl Acetate (EVA) or Polyethylene (PE)
treated with the cross-linking treatment by an electron beam
irradiation.
29. The ice maker of claim 25, wherein the second insulating layer
is made of EVA or PE added with a flame retardant and treated with
the cross-linking treatment by the electron beam irradiation.
30. The ice maker of claim 25, wherein the second insulating layer
is a shrink tube treated with the cross-linking treatment by the
electron beam irradiation.
31. The ice maker of claim 26, the second insulating layer is made
of Cross Linking Polyethylene (XLPE).
32. (canceled)
33. (canceled)
34. (canceled)
Description
TECHNICAL FIELD
[0001] The present invention relates to an ice maker, and more
particularly, to an ice maker provided with a heater which serves
ice to be easily separated from an ice tray.
BACKGROUND ART
[0002] In general, a refrigerator is used to store foods for a long
time so as not to spoil them, but recently it is a trend that a
variety of functions have been added in addition to the storage of
foods. Conventionally, a function of ice-making is one of the
functions provided in the refrigerator, but an ice maker which
generates ice automatically by automating an ice-making process and
stores the generated ice in an ice bank is one of the items which
improve the ease of use.
[0003] Such an ice maker may be classified as a twist method, an
ejector method and a rotation method, depending on the method of
ice-separation.
[0004] The twist method is a method that makes ice to drop by
twisting an ice tray. The ejector method is a method that makes ice
to draw up from the ice tray and then to drop by an ejector
installed on the upper side of the ice tray. The rotation method is
a method that makes ice to drop by rotating the ice tray.
[0005] Such types of ice makers may serve the entire size of the
ice makers to be slimmed. Accordingly, the effective volume in a
refrigerator may be expanded, and also the configuration of
equipment may also be simplified. However, in case where the
ice-separation from the ice tray is not fulfilled smoothly in such
types of ice makers, the ice maker may not be operated
efficiently.
[0006] In view of such a problem, it is disclosed an ice maker
provided with a heater in Korean Patent Laid-Open Publication No.
2006-0009405. The disclosed ice maker is configured to be equipped
with a heater for ice-separation to apply heat to the ice tray.
[0007] It is disclosed an ice maker for a refrigerator in Korean
Patent Laid-Open Publication No. 2010-0138373. The disclosed ice
maker includes a water supply unit which is installed on one side
of an ice tray and supplies water to the ice tray; a lever for
ice-separation which is assembled rotatably between a driving unit
installed on one side of the ice tray and the water supply unit,
and is rotated by a motor mounted in the driving unit; a heater for
ice-separation which applies heat to the ice tray to separate ice
from the ice tray; an inserting recess formed to be adjacent to the
heater for ice-separation; a fitting recess formed on one side of
the inserting recess; and a bimetal or a thermal fuse which is
inserted into the inserting recess and cuts off the power to the
heater for ice-separation at a predetermined temperature.
[0008] The ice maker as described above is configured to be
equipped with a heater on the lower portion of the ice tray to
provide a smooth ice-separation. The heater is configured to have a
hot wire installed inside the metal tube. The heater is also
configured in a way that the heater is installed in a lead-in
recess formed on the lower portion of the ice tray and is supported
by a jaw formed on the end side within the lead-in recess.
[0009] Such the heater formed on the lower portion of the ice tray
does not get in a contact with the ice tray smoothly, and thereby
there is a problem that it takes a relatively longer time to heat
the lower surface of the ice tray to a predetermined temperature.
When the heater is operated for a longer time, the overall
temperature of the ice-making chamber having the ice maker therein
is increased. In this case, after the ice within the ice tray is
separated and moved to the ice bank, when making ice again with the
supplied ice-making water, it takes a longer time to cool the ice
tray to the ice-making temperature.
[0010] Therefore, the total ice-making time required for completing
a cycle of ice-making process becomes longer, and the power
consumption required for the ice-making process becomes higher.
[0011] In addition, since the heater is installed in a state that
the lower portion of the ice tray is exposed to the outside, the
heat loss generated from the heater is relatively higher.
DISCLOSURE
Technical Problem
[0012] In view of the above, in order to solve the above described
problems, the present invention provides an ice maker which is
capable of reducing a heat loss of a heater installed in the lower
portion of an ice tray for ice-separation and capable of reducing a
time required for heating the ice tray to a predetermined
temperature of ice-separation by getting the heater in a close
contact with the ice tray.
[0013] Further, the present invention provides an ice maker which
is capable of fixing reliably a thermo limiter for preventing
overheating when coupling to a base cover which is coupled to the
ice tray.
TECHNICAL SOLUTION
[0014] An ice maker of the present invention to solve the above
technical problem includes an ice tray;
[0015] at least one heater housing which is formed in the ice tray;
a heater which is equipped with a soft or an elastic outer shell
and is accommodated in a close contact within the heater housing,
and heats the ice tray; and a base cover which is coupled to the
ice tray, and is equipped with a support rib which pressurizes the
heater mounted in the heater housing to make the heater getting a
close contact with the heater housing.
ADVANTAGEOUS EFFECTS
[0016] An ice maker in accordance with the present invention is
capable of widening an area where a heater gets in a direct contact
with an ice tray, and is capable of forming the heater over the
entire area of the ice tray, and thereby it is possible to reduce a
time required for heating the ice tray to a predetermined
temperature. Also, it is capable of reducing an increase of the
overall temperature of an ice-making chamber having an ice maker
therein, and thereby when ice is made with the supplied ice-making
water after the ice within the ice tray is separated and moved to
an ice bank, it is possible to reduce a time required for cooling
the ice tray to an ice-making temperature. With the help of the
above described effects on time saving, it is possible to reduce a
total ice-making time required for completing a cycle of ice-making
process and also power consumption to be consumed for an ice-making
process. In addition, since it is capable of getting the heater in
a close contact with the ice tray, it is possible to improve an
efficiency of heat transfer.
[0017] Further, the ice maker of the present invention is capable
of supporting the heater in the lower portion of the ice tray, and
thereby it is possible to prevent for the heater from being
deviated from the heater housing. Also, by getting the heater in a
seal within the heater housing, even if a chilly air is supplied to
the ice tray, it is possible to prevent for the chilly air from
getting in a contact with the heater. In addition, since the heater
is installed in the lower portion of the ice tray, it is possible
to easily check the installed state of the heater with the naked
eye.
[0018] Furthermore, in accordance with the ice maker of the present
invention, an overheating sensor for sensing an overheating of the
heater is mounting in the ice maker, during coupling a base cover
which surrounds the heater installed in the ice tray, and thereby
it is possible to reduce a work load required for mounting the
overheating sensor.
DESCRIPTION OF DRAWINGS
[0019] FIG. 1 is a perspective view of an ice maker in accordance
with the present invention.
[0020] FIG. 2 is an exploded perspective view illustrating a state
that an ice tray, a heater and a base cover are mounted on an ice
maker in accordance with the present invention.
[0021] FIG. 3 is a cross-sectional view of an ice tray in which a
heater is installed.
[0022] FIG. 4 is a perspective view illustrating an embodiment of a
heater.
[0023] FIG. 5 is a perspective view illustrating another embodiment
of a heater.
[0024] FIG. 6 is a cross-sectional view illustrating a buffer
portion against a length of a heater formed in an ice tray.
[0025] FIGS. 7A, 7B and 7C are views illustrating an example of an
ice tray having a heater installed therein, in an ice maker in
accordance with an embodiment of the present invention.
[0026] FIG. 8 is a cross-sectional view illustrating an example
where a heater is accommodated in a heater housing, in an ice maker
in accordance with an embodiment of the present invention.
[0027] FIG. 9 is a cross-sectional view illustrating another
example of an ice tray having a heater that is accommodated in a
heater housing, in an ice maker in accordance with an embodiment of
the present invention.
[0028] FIG. 10 is a perspective view illustrating another example
of an ice tray in which a heater of the present invention is
installed.
[0029] FIG. 11 is a cross-sectional view of the ice tray shown in
FIG. 10.
[0030] FIGS. 12A, 12B, 12C, 12D and 12E are views illustrating
different examples of a support rib of a base cover of the present
invention.
[0031] FIG. 13 is a side partial cut-away view illustrating an ice
maker of the present invention
[0032] FIG. 14 is an exploded partial cut-away perspective view
illustrating an example where an overheating sensor is installed by
an ice tray and a base cover.
[0033] FIG. 15 is an exploded partial cut-away perspective view
illustrating another example where an overheating sensor is
installed by an ice tray and a base cover.
[0034] FIG. 16 is an exploded partial cut-away perspective view
illustrating another example where an overheating sensor is
installed by an ice tray and a base cover.
[0035] FIGS. 17A, 17B and 17C are graphs illustrating a comparison
of performance of a heater in accordance with an embodiment of the
present invention and a heater in accordance with the prior
art.
BEST MODE
[0036] Hereinafter, embodiments of an ice maker of the present
invention will be described with reference to FIGS. 1 through 17.
However, these are merely exemplary embodiments and the present
invention is not limited thereto.
[0037] In the following description, well-known functions and/or
constitutions will not be described in detail if they would
unnecessarily obscure the features of the present invention.
Further, the terms to be described below are defined in
consideration of their functions in the embodiments of the present
invention and may vary depending on a user's or operator's
intention or practice. Accordingly, the definition may be made on a
basis of the content throughout the specification.
[0038] The technical spirit of the present invention is determined
by the claims, and the following embodiments are just means for
describing effectively the progressive technical spirit of the
present invention to those skilled in the art within the scope of
the present invention.
[0039] Referring to FIGS. 1 through 3, an ice maker 10 in
accordance with the present invention includes an ice tray 20, an
ejector 11, a control unit 12, a side guide 13, an ice bank 14, a
water supply pipe 15, a water supply cup 16, a full ice lever 17
and a heater 30.
[0040] In the ice maker 10, the ice tray 20 has an ice-making space
to contain water therein. In the interior of the ice tray 20, a
plurality of partition walls are formed so as for the ice-making
space to be divided into a plurality of subspaces. Each of the
ice-making subspaces divided in the interior of the ice tray 20 may
be respectively formed in correspondence with each of ejector pins
11b, which will be described later.
[0041] The ice tray 20 is supplied with water (i.e., ice-making
water) through the water supply pipe 15 and the water supply cup
16. The water contained in the ice-making space within the ice tray
20 is then frozen by a chilly air of an ice-making chamber (not
shown).
[0042] The control unit 12 drives a motor (not shown) to rotate the
ejector 11 in the clockwise direction. The ejector 11 includes an
ejector shaft 11a and a plurality of ejector pins 11b formed spaced
apart from each other in the ejector shaft 11a. When the motor
rotates the ejector shaft 11a in the clockwise direction, the
ejector pins 11b while rotating together with the ejector shaft 11a
in the clockwise direction separates the ice within the ice tray 20
from the ice tray 20 and pushes the ice upwards. The ice pushed
upwards by the ejector pins 11b falls into the ice bank 108 by
riding down the side guide 13 formed at one side of the ice tray
20.
[0043] As shown in FIG. 3, on the outer circumferential surface of
the ice tray 20, at least one heater housing 21 for accommodating
the heater 30 is formed. For example, the heater housing 21 may
include a pair of protrusions 21a, 21b protruded from the outer
circumferential surface of the ice tray 20 and a heater
accommodating recess 21c formed the protrusions. However, the
heater housing 21 is not limited thereto, and may be formed in a
variety of forms other than that can accommodate the heater 30. For
example, the heater housing 21 may be formed of only an
accommodating recess which is formed by leading on the outer
circumferential surface of the ice tray 20 without any separate
protrusion.
[0044] The heater 30 which is mounted in the heater housing 21 may
be a flexible one, as shown in FIG. 4. The heater 30 may include a
heating unit 31, a first insulating layer 32a which is formed so as
to surround the heating unit 31, and a second insulating layer 32b
which is formed so as to surround the first insulating layer
32a.
[0045] The heating unit 31 serves to generate heat when a voltage
is applied thereto. The heating unit 31 may include one or more hot
wire (e.g., a nickel-chromium wire, or copper-nickel wire, etc.).
However, the heating unit 31 is not limited thereto, and may be
formed in a shape in which a glass fiber is wound on the hot wire,
or a shape in which the hot wire is wound on the glass fiber.
[0046] Then, the first insulating layer 32a may be formed by
extruding with a silicone or a rubber, and the second insulating
layer 32b may be formed of Ethylene Vinyl Acetate (EVA) or
Polyethylene (PE) added with a flame retardant. For example, the
second insulating layer 32b may be formed with a cross-linking
treatment by electron beam irradiation. In case where the second
insulating layer 32b is formed with the cross-linking treatment by
electron beam irradiation, it is possible to improve the heat
resistance of the second insulating layer 32b and also compensate
the brittleness of the second insulating layer 32b.
[0047] For example, in case where the second insulating layer 32b
is formed of PE added with a flame retardant, when irradiating an
accelerated electron beams to the second insulating layer 32b, H
ion is dissociated from PE chain to generate radicals. The
cross-linking is proceeded by a combination of the radicals. During
this process, PE comes to have a reticular structure by the
combination of the radicals, and thereby it is possible to improve
the heat resistance of the second insulating layer 32b and also
compensate the brittleness of the second insulating layer 32b. The
second insulating layer 32b may be formed by an extruding process
on the first insulating layer 32a.
[0048] Since the heater 30 which may be a flexible type is formed
in a shape of a zigzag on the outer circumferential surface of the
ice tray 20, the flexible heater 30 is subject to bending in
various portions. In this case, each of the bent portions is
vulnerable to crack due to continuous stresses and consequently may
be damaged. However, the second insulating layer 32b is treated
with the cross-linking treatment by the electron beam irradiation,
and thus the heater 30 is already compensated for the brittleness.
Even if the heater 30 is installed to be bent, therefore, it is
possible to prevent for a crack to occur in the flexible heater 30.
In this embodiment, the second insulating layer 32b is described to
be made of EVA or PE treated with the cross-linking by the electron
beam irradiation. However, the second insulating layer 32b is not
limited thereto, and may be used with a shrink tube. The shrink
tube may be made of a silicone or a rubber elastomer. In this case,
the second insulating layer 32b can be improved in the
air-tightness and also is able to withstand the mechanical shock.
Further, the shrink tube may be a shrink tube treated with the
cross-linking by the electron beam irradiation. In addition, the
second insulating layer 32b may be formed of Cross-Linking
Polyethylene (XLPE). XLPE is treated with the cross-linking by a
mixture of an organic vulcanized agent and PE to make the structure
of PE to the linked state (i.e., cross-linked state) in order to
provide the thermosetting and viscoelastic properties to PE.
[0049] Referring to FIG. 5, the flexible heater 30 may include a
heating unit 31 and an insulating layer 34 surrounding the heating
unit 31. The insulating layer 34 may be EVA or PE treated with the
cross-linking by the electron beam irradiation. However, the
insulating layer 34 is not limited thereto, and may be formed of a
XLPE as well.
[0050] An example of such type of the heater 30 may be a cord
heater, but is not limited thereto.
[0051] In case of using the cord heater as the heater 30, the cord
heater may be flexible and may be formed with a smaller diameter
(e.g., 2.about.4 mm) Consequently, when the heater 30 is formed at
the outer circumferential surface of the ice tray 20, an area where
the heater 30 and the ice tray 20 get in contact each other may be
larger. In other words, by forming the heater 30 in a zigzag form
on the outer circumferential surface of the ice tray 20, it is
possible to improve the area where the heater 30 and the ice tray
20 get in contact each.
[0052] In this embodiment, the heater 30 is shown to have a zigzag
form on the outer circumferential surface of the ice tray 20, which
however is not limited thereto, and additionally may be formed in a
variety of forms (e.g., spiral form and the like) in which the
heater 30 may be placed compactly on the outer circumferential
surface of the ice tray 20. Further, the heater housing 21 is shown
to be formed continuously along the heater 30, which however is not
limited thereto, and may be formed in a cut-off at regular
intervals.
[0053] As described above, in case of using the cord heater as the
heater 30, the area where the heater 30 gets in a direct contact
with the ice tray 20 may become larger, and the heater 30 may be
formed over the entire area of the ice tray 20. Therefore, it is
possible to reduce the time required for heating the ice tray 20 to
a predetermined temperature. In this case, since the overall
temperature increasing of the ice-making chamber having the ice
maker 10 therein can be reduced, after the ice within the ice tray
20 is ejected to the ice bank 14, when another ice is made again
with the supplied ice-making water, it is possible to reduce the
time required for cooling the ice tray 20 to the ice-making
temperature. Consequently, it is possible to reduce the total time
required for completing a cycle of ice-making process, and also to
reduce the power consumption required for the ice-making
process.
[0054] Also, since the heat transfer distance between the heating
unit 31 and the ice tray 20 is short (about 1.about.2 mm), it is
possible to heat the ice tray 20 to the predetermined temperature
even with a low power (e.g., 50 Watt), thereby reducing the power
consumption required for operating the heater 106 itself
[0055] Meanwhile, as shown in FIG. 6, there is formed a heater
length buffer 22 in accordance with an error of length of the
heater on the end of the heater housing 21. The heater length
buffer 22 includes a molding accommodating recess 22a having a
width larger than a heater accommodating recess 21c, which is
formed at the end side of the heater accommodating recess 21, and a
molding portion 22b being inserted into the molding accommodating
recess 22a, which is formed at the connection area of the heater 30
and a lead wire 35.
[0056] The molding accommodating recess 22a may be formed to be
extended from the accommodating recess 21c of the heater housing
21. When the molding portion 22b is accommodated in the molding
accommodating recess 22a, the molding accommodating recess 22a may
be formed so as for free spaces to exist in the right and left of
the molding portion 22b. In this case, even if the length of the
heater 30 is prepared with a little shorter or longer than the
reference value, the heater 30 is allowed to be used without any
change of design. In other words, the free spaces existing in the
right and left of the molding portion 22b within the molding
accommodating recess 22a may be referred to as a buffer space to
supplement any error in the length of the heater 30.
[0057] Referring to FIG. 7A showing the heater accommodating recess
21c of the heater housing 21 formed on the ice tray 20, the bottom
surface of the accommodating recess 21c may be formed in a
semi-circular shape, and the both sides of the accommodating recess
21c may be formed in flat surfaces parallel to each other. Then,
the heater 30 which is inserted into the accommodating recess 21c
may be formed in a circular shape. In this case, more than half of
the outer circumferential surface of the heater 30 gets in contact
with the ice tray 30.
[0058] A contact holding member 26 may then be formed between the
heater 30 and the inner wall of the heater accommodating recess
21c. The contact holding member 26 has a role for an empty space or
air not to exist between the heater 30 and the inner wall of the
heater accommodating recess 21c. In other words, the contact
holding member 26 has a role for the heater 30 to be in a close
contact with the inner wall of the heater accommodating recess 21c.
As the contact holding member 26, for example, an adhesive material
may be used. Accordingly, the heater 30 may be fixed to the heater
accommodating recess 21c while getting in a close contact with the
inner wall of the accommodating recess 21c. For example, when a
thermal conductive adhesive material is used as the contact holding
member 21c, it is possible to increase a thermal conductivity from
the heater 30 to the ice tray 20. Further, in the empty space
between the heater 30 and the inner wall of the heater
accommodating recess 21c at the lower end of the heater
accommodating recess 21c, a separate sealing member (not shown) may
be filled. Accordingly, it is possible for the heater 30 to be
fixed within the heater accommodating recess 21c while reducing the
heat loss. The sealing member (not shown) may be formed of the same
material as the contact holding member 26.
[0059] Referring to FIG. 7B, the cross section of the heater
accommodating recess 21c may be formed in a rectangular shape
having an open end, and the insulating layer 34 or the second
insulating layer 32b of the heater 30 may be formed in a
rectangular shape corresponding to the heater accommodating recess
21c. In this configuration, when the heater 30 is inserted into the
heater accommodating recess 21c, about 3/4 of the entire outer
circumferential surface area of the heater 30 may get in contact
with the heater accommodating recess 21c. Therefore, it is possible
to increase the efficiency of heat transfer from the heater 30 to
the ice tray 20. Also, the area of the heater 30 to be exposed to
the outside is minimized, thereby reducing the heat loss.
[0060] Referring to FIG. 7C, the top of the heater accommodating
recess 21c is formed of a semi-circular shape, and the cross
section of the heater 30 being inserted into the heater
accommodating recess 21c is formed in a semi-circular shape. In
this case, it is possible to expand the area where the heater 30
gets in a contact with the ice tray 20, and also to reduce the area
where the heater 30 is exposed to the outside.
[0061] Meanwhile, in FIGS. 7A, 7B and 7C, it is described that the
heater 30 is fixed to the heater accommodating recess 21c through
the fitting by inserting method. However, the method of fixing the
heater 30 to the heater accommodating recess 21c is not limited
thereto. For example, the heater 30 may be fixed to the heater
accommodating recess 21c by using both of the fitting by inserting
method and adhering method, and also may be fixed to the heater
accommodating recess 21c using a variety of fixing methods other
than those methods.
[0062] FIG. 8 is a cross-sectional view illustrating another
example where a heater is accommodated in a heater housing, in an
ice maker in accordance with an embodiment of the present
invention.
[0063] Referring to FIG. 8, an additional protrusion 35 may be
formed on the outer circumferential surface of the heater 30. In
this regard, the additional protrusion 35 may be formed so as to be
inclined to the downward direction. When the heater 30 is
pressurized to the upper direction after placing at the lower
portion of the heater accommodating recess 21c, since the second
insulating layer 32b or the insulating layer 34 is made of the soft
insulating material, the additional protrusion 35 is folded by the
inner wall of the heater accommodating recess 21c, and becomes to
be in a close contact with the outer circumferential surface of the
heater 30. After the heater 30 is inserted into the heater
accommodating recess 21c, the heater 30 is capable of_being tightly
jammed by the additional protrusion 35 within the heater
accommodating recess 21c, and thereby the heater 30 is prevented
from getting out from the heater accommodating recess 21c. In this
embodiment, the additional protrusion 35 is shown to be a single,
which however is not limited thereto, and may be formed in two or
more. In this case, when the heater 30 is inserted into the heater
accommodating recess 21c, the additional protrusion 35 is inserted
into a additional protrusion inserting recess (not shown), and
thereby the heater 30 is supported by fixing.
[0064] In accordance with the present invention, the protrusions
21a, 21b protruded on the outer circumferential surface of the ice
tray 20 for forming the heater accommodating recess may be formed
as a pair of protrusions 21a, 21b which are protruded in a
horizontal direction on the outer circumferential surface of the
ice tray 20, as shown in FIG. 9. In this case, the heater 30 is
easily installed in the heater accommodating recess 21c by the pair
of protrusions 21a, 21b.
[0065] FIGS. 10 and 11 are views illustrating another embodiment of
an ice tray, wherein FIG. 10 is a view showing a lower surface of
the ice tray, and FIG. 11 is a view showing a cross section of the
ice tray.
[0066] Referring to FIGS. 10 and 11, the heater housing 21 is
formed to be longer than the adjacent protrusion 26 of a pair of
protrusions 25, 26 which are protruded from the outer
circumferential surface of the ice tray 20 to form a heater
accommodating recess. In this case, when the heater 30 is turned
off, an area where the chilly air gets in contact with the ice tray
20 becomes wider, and thereby it is possible to improve the
radiating effect of the ice tray 20. When describing in more
detail, as shown in FIG. 11, a first to an eighth heater
accommodating recesses 21a-1 to 21a-8 may be formed sequentially
from one side of the ice tray 20 to the other side of the ice tray
20. In FIG. 11, eight heater accommodating recesses 21a-1 to 21a-8
are shown to be formed on the outer circumferential surface of the
ice tray 20, which however is not limited thereto, and may be
formed with various numbers other than the above.
[0067] Between the pair of the first protrusion 25 and the second
protrusion 26 forming a heater accommodating recess respectively at
the first to eighth heater housings 21a-1 to 21a-8, the first
protrusion 25 formed adjacent to one side of the ice tray 20 may be
formed with a length corresponding to the diameter of the heater 30
on the outer circumferential surface of the ice tray 20. In this
case, when the operator looks the ice tray 20 on one side of the
ice tray 30, it is possible to check with the naked eye whether the
heater 30 is inserted in close contact within each of the heater
housings 21a-1 to 21a-8. On the contrary, the second protrusion 26
of the pair of the first protrusion 25 and the second protrusion 26
may be formed with a length longer than that of the first
protrusion 25 in the first heater housing 21a-1, but may be formed
not to be higher than the first protrusion 25 forming the adjacent
heater housing. For example, the second protrusion 26 of the first
heater housing 21a-1 is formed not to protrude higher than the
first protrusion 25 of the second heater housing 21a-2. In case
where the second protrusion 26 of the first heater housing 21a-1 is
formed to protrude higher than the first protrusion 25 of the
second heater housing 21a-2, when the operator looks the ice tray
20 on one side of the ice tray 20, it is difficult to check with
naked eye whether the heater 30 is inserted in close contact within
the second heater housing 21a-2.
[0068] In case where the heater 30 turns off in operating, the
second protrusion 26 has a role of a radiating fin for radiating
the heat of the ice tray 20 heated by the heater 30 to the outside.
In other words, after ice-separation of the ice within the ice tray
20, the ice tray 20 is ready to produce ice again by being supplied
the ice-making water. In this case, in order to cool the ice tray
20 to the ice-making temperature efficiently, the heat of the ice
tray 20 provided by the heater 30 must be quickly released to the
outside. In consideration of the above reason, the second
protrusion 26 is formed with a length longer than that of the first
protrusion 25 in order to expand the area where the ice tray 20
gets in contact with the chilly air, and thereby it is possible to
cool rapidly the ice tray 20 to the ice-making temperature. As
described above, the second protrusion 26 has a role of the
radiating fin as well.
[0069] As shown in FIGS. 1, 2 and 12, the ice maker 10 in
accordance with the present invention may further include a base
cover 40 provided on the lower portion of the ice tray thereof.
[0070] The base cover 40 is coupled to the ice tray 20 so as to
surround the lower part of the ice tray 20. The base cover 40
includes support ribs 41 which support the heater 30 being inserted
into the heater housing 21c of the heater supporting portion 21
formed at the lower portion of the ice tray 20. The support ribs 41
may be formed on the inner surface of the base cover 40
corresponding to the heater accommodating recess 12c. The support
ribs 41 may has a role of the cover covering the end of the heater
accommodating recess 21c. A plurality of through holes 42 are
formed in the base cover 40 through which the chilly air is
transferred to the ice tray 20 preferably without any interference.
It is also preferred that a space between each of the support ribs
41 becomes a pathway of transfer for the chilly air. In addition, a
shield 43 may be formed in the terminal of each of the support ribs
41. The shield 43 may be formed to be extended from side to side at
the terminal of the support rib 41. In this regard, the shield 147
may be formed while closing the inlet of the heater accommodation
recess 21c. Then, the heater accommodating recess 21c having the
heater 30 therein becomes the state that is shielded from the
outside. In this description, the shield 43 is described as being
formed to be extended from side to side at the terminal of the
support rib 41, which however is not limited thereto, and may be
formed separately from the support rib 41 and coupled at the
terminal of the support rib 41.
[0071] FIGS. 12A, 12B, 12C, 12D and 12E are different examples of a
support rib to be installed in a base cover, in accordance with
another embodiment of the present invention.
[0072] Referring to FIG. 12A, a shield is not formed at the
terminal of the support rib 41, but may be formed by contacting
with the heater 30 to be installed in the heater accommodating
recess 21c. According to the configuration, the support rib 41
becomes to support the heater 30, and thereby the heater 30 can be
prevented from getting off from the heater accommodating recess
21c.
[0073] Referring to FIG. 12B, the width of the shield 43 formed at
the terminal of the support rib 41 is formed with the substantially
same width as the heater accommodating recess, and supports the
heater 30 in the state of being inserted into the heater
accommodating recess 21c. According to the configuration, the
shield 43 may shield the heater 30 from the outside while
supporting the heater 30.
[0074] Referring to FIG. 12c, the shield 43 formed at the terminal
of the support rib 41 may be formed while closing the inlet of the
heater accommodating recess 21c. On the upper surface side of the
shield 43, a heater support protrusion 43a being in contact with
the heater 30 may be formed. According to the configuration, the
area where the shield 43 gets in a contact with the heater 30 is
reduced, and thereby the shield 43 and the support rib 41 can be
prevented from being deformed.
[0075] In other words, in case where the base cover 40 and the
support rib 41 are made of a synthetic resin respectively, when the
shield 43 gets in a contact with the heater 30, it may result in
deformation in the shield 43 and the support rib 41 due to the heat
generated by the heater. In this case, the heater support
protrusion 43a is formed on the upper surface of the shield 43 in
order to reduce the area where the shield 43 gets in a contact with
the heater 30, and thereby it is possible to reduce a heat transfer
from the heater 30 to the shield 43. Accordingly, the shield 43 and
the support rib 41 can be prevented from being deformed due to the
heater 30.
[0076] The shield 43 formed at an end of the support rib 41 may be
formed with a width same as the width between the first protrusion
25 and the second protrusion 26 forming the heater accommodating
recess and the outer edge, as shown in FIG. 12D, or may be formed
so as to surround the first protrusion 25 and the second protrusion
26 forming the heater accommodating recess, as shown in FIG.
12E.
[0077] In addition, a sealing member (not shown) may be filled in
the empty space between the inner wall of the heater accommodating
recess 21c and the heater 30 within the heater accommodating recess
21c. In this case, it is possible to seal the heater 30 within the
heater accommodating recess 21c to reduce the heat loss. Further,
the sealing member (not shown) has a role of a kind of buffer, and
thereby the shield 43 and the support rib 41 can be prevented from
being deformed due to the heat generated by the heater 30.
[0078] On the other hand, as shown in FIGS. 2, 13, 14 and 15, a
first overheating sensor 51 and a second overheating sensor 52 may
be installed in the first lead wire 36 and the second lead wire 37
connected to both ends of the heater, respectively. The overheating
sensors may be formed in one side of the first lead wire and the
second lead wire as well.
[0079] The first lead wire 36 and the second lead wire 37 are
connected to the terminal of a main board 50 installed in a control
box 12. The first overheating sensor 51 and the second overheating
sensor 52 serve to prevent the heater 30 from being overheated. For
example, the first overheating sensor 51 and the second overheating
sensor 52 may detect whether the temperature of the heater 30
exceeds a predetermined threshold temperature in order to prevent
the heater 30 from being overheated. It is, however, not limited
thereto, and the first overheating sensor 51 and the second
overheating sensor 52 may detect whether an overcurrent flows
through the heater 30 in order to prevent the heater 30 from being
overheated.
[0080] In addition, there is provided a sensor support unit 60 in
one side of the base cover 40. The sensor support unit 60 includes
a support member 63 in which coupling portions 61, 62 are formed.
The coupling portions 61, 62 are extended between the control box
12 and the ice tray 20 and are connected to the first overheating
sensor 51 and the second overheating sensor 52. It is preferred
that the support member 63 of the sensor support unit 60 is placed
between the control box 12 and the ice tray 20 so as for an
interference not to occur upon coupling the base cover 40 and the
ice tray 20 each other. The coupling portions 61, 62 may have an
inserting recess formed on the side of the support member 63 so as
for the first overheating sensor 51 and the second overheating
sensor 52 to be coupled. As described above, the first overheating
sensor 51 and the second overheating sensor 52 may be coupled by
being inserted into the inserting recess forming the coupling
portions 61, 62, which however is not limited thereto, and may be
coupled by a variety of methods other than the above.
[0081] In this embodiment, the support member 63 is shown in a way
that the coupling portions 61, 62 are formed integrally with the
base cover 40. However, this is not limited thereto, and the
support member 63 may be manufactured separately from the base
cover 40 and then may be coupled to the base cover 40. The first
overheating sensor 51 and the second overheating sensor 52 may get
in contacts with the ice tray 20 while being supported by the
coupling portions 61, 62.
[0082] In addition, the support member 63 may have a first
inserting hole 64 formed therein. When the first overheating sensor
51 and the second overheating sensor 52 are inserted through the
first inserting hole 64, the first inserting hole 64 is coupled to
each of the coupling portions 61, 62. Then, the first lead wire 36
and the second lead wire 37 are drawn out through the first
inserting hole 64 and are respectively connected to the terminal of
the main board 50. As shown in FIG. 15, the first inserting hole 64
may have a second inserting hole 65 formed in the lower portion
thereof. Accordingly, the lead wires to be connected to the first
overheating sensor 51 or the second overheating sensor 52 may be
inserted separately. In the side of the control box of the support
member 63, a molding housing 66 to which the molding portion 22b of
the heater is fixed may be formed. In the molding housing 66, the
molding portion 22b may be fixed. When the molding portion 22b is
accommodated in the molding housing 66, the molding housing 66 may
be formed so as for free spaces to exist in the left and right or
in the top and bottom of the molding portion 22b. In this case,
even if the length of the heater 30 is manufactured in a slightly
shorter or longer than the reference value, it is possible to use
the heater 30 without any change of design. In other words, the
free spaces which exist in the right and left or in the top or
bottom of the molding portion may be referred to as a buffer space
supplementing an error in length of the heater. In this case, in
the side of the control box 12 corresponding to the molding housing
66, a lead-in portion is formed so as for the molding housing 66 to
be inserted.
[0083] On the other hand, as shown in FIG. 16, the support member
63 may have a though hole 65 which is communicated with the
coupling portions 61, 62 formed therein so as for the first
overheating sensor 51 and the second overheating sensor 52 to be
inserted respectively. The through hole 65 is allowed for the first
overheating sensor 51 and the second overheating sensor 52 to be
inserted respectively in a state that the base cover 40 and the ice
tray 20 are coupled each other.
[0084] In accordance with an embodiment of the present invention,
since the first overheating sensor 51 and the second overheating
sensor 52 are coupled to the coupling portions 61, 62 formed in the
support member 63 of the base cover 40, it is possible to fix
stably the first overheating sensor 51 and the second overheating
sensor 52. Also, the task of fixing the first overheating sensor 51
and the second overheating sensor 52 comes to be easy, and the
first lead wire 36 and the second lead wire 37 can be clearly
arranged.
[0085] Further, since the control box 12 pressurizes the support
member 63 when being coupled to the ice tray 20, the first
overheating sensor 51 and the second overheating sensor 52 maintain
close contacts with the ice tray 20, and thereby it is possible to
accurately detect whether the heater 30 gets overheating. In other
words, the first overheating sensor 51 and the second overheating
sensor 52 are primarily brought into close contacts with the ice
tray 20 by the base cover 40, and are secondarily brought into
further close contacts with the ice tray 20 by the control box
12.
[0086] FIGS. 17A, 17B and 17C are graphs illustrating a comparison
of performance of a heater in accordance with an embodiment of the
present invention and a heater in accordance with the prior
art.
[0087] Referring to FIG. 17A, it can be seen that the heater 30 in
accordance with an embodiment of the present invention takes a
first time (t1) to heat the ice tray 20 to the predetermined
temperature, and on the contrary, the heater in accordance with the
prior art takes a second time (t2) longer than the first time (t1)
to heat the ice tray 20 to the predetermined temperature. This is
contributed that by forming the heater 30 in the form of a cord
heater, the area where the heater 30 gets in a direct contact with
the ice tray 20 is widened, and by forming the heater 30 over the
entire area of the ice tray 20, the entire area of the ice tray 20
is heated uniformly. In addition, this is contributed that the
chilly air is shielded not to get in contact with the heater 30 by
the shield.
[0088] Referring to FIG. 17B, it can be seen that the power
required for the heater 30 in accordance with an embodiment of the
present invention is lower than the power required for the heater
in accordance with the prior art. This is contributed that the
heater 30 in accordance with an embodiment of the present invention
has a relatively shorter distance of heat transfer, and thereby it
is possible to heat the ice tray 20 to the predetermined
temperature even at a low power.
[0089] Referring to FIG. 17C, it can be seen that in case of using
the heater 30 in accordance with an embodiment of the present
invention, the temperature of the ice-making chamber is gradually
increased with the not high temperature increase, but in case of
using the heater in accordance with the prior art, the ice-making
chamber is rapidly increased with the high temperature increase.
This is contributed that as shown in FIGS. 17A and 17B, the heater
30 in accordance with an embodiment of the present invention is
capable of heating the ice tray 20 to the predetermined temperature
in a short time even using a low power.
[0090] While the embodiments of the present disclosure have been
illustrated and described as described above, it will be
appreciated by those skilled in the art that various modifications,
additions and substitutions to the embodiments are possible,
without departing from the scope of the present disclosure.
Therefore, the scope of the present disclosure is not limited to
the described embodiments, but should be defined by the
accompanying claims and equivalents thereof.
* * * * *