U.S. patent application number 14/840036 was filed with the patent office on 2016-12-22 for refrigerator and method of manufacturing ice maker therefor.
The applicant listed for this patent is Dongbu Daewoo Electronics Corporation. Invention is credited to Sung Jin YANG.
Application Number | 20160370062 14/840036 |
Document ID | / |
Family ID | 57587737 |
Filed Date | 2016-12-22 |
United States Patent
Application |
20160370062 |
Kind Code |
A1 |
YANG; Sung Jin |
December 22, 2016 |
REFRIGERATOR AND METHOD OF MANUFACTURING ICE MAKER THEREFOR
Abstract
According to an embodiment, an ice maker comprises: a main body
having a cooling space supplied with the cold air generated by a
cooling module; an ice making assembly comprising an ice tray
arranged in the cooling space to generate ice, a cold air guide
module disposed at a lower side of the ice tray and configured to
guide the cold air supplied from the cooling module to the lower
side of the ice tray, and a rotation module configured for rotating
at least one of the ice tray and rotating an ejector for ejecting
the ice from the ice tray; an ice bucket disposed at a lower side
of the ice making assembly configured to receive the ice from the
ice tray; and a full ice detection module. The full ice detection
module comprises a first sensor coupled to a lower portion of the
rotation module and a second sensor coupled to a lower portion of
the cold air guide section, and detecting whether or not the ice
bucket is full of the ice by operative interconnection of the first
and second sensors.
Inventors: |
YANG; Sung Jin; (Seoul,
KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Dongbu Daewoo Electronics Corporation |
Seoul |
|
KR |
|
|
Family ID: |
57587737 |
Appl. No.: |
14/840036 |
Filed: |
August 30, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F25C 5/22 20180101; F25C
5/187 20130101 |
International
Class: |
F25C 1/10 20060101
F25C001/10; F25D 29/00 20060101 F25D029/00; F25D 11/00 20060101
F25D011/00; F25D 23/00 20060101 F25D023/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 17, 2015 |
KR |
10-2015-0086161 |
Claims
1. A refrigerator comprising: a case comprising a food storage
space; a cooling module configured to generate cold air; a door
disposed on the case to seal the food storage space; and an ice
maker installed in at least one of the food storage space and the
door, wherein the ice maker comprises: a main body having a cooling
space for receiving the cold air generated by the cooling module;
an ice making assembly comprising: an ice tray disposed in the
cooling space to generate ice, a cold air guide module disposed at
a lower side of the ice tray and configured to guide the cold air
supplied from the cooling module to the lower side of the ice tray;
and a rotation module configured for rotating at least one of the
ice tray and an ejector for ejecting the ice from the ice tray; an
ice bucket disposed at a lower side of the ice making assembly to
receive the ice from the ice tray; and a full ice detection module
comprising a first sensor coupled to a lower portion of the
rotation module and a second sensor coupled to a lower portion of
the cold air guide module, and detecting whether or not the ice
bucket is full by operative interconnection of the first and second
sensors.
2. The refrigerator according to claim 1, wherein the first sensor
is inserted into a first mounting portion disposed in the lower
portion of the rotation module and the second sensor is inserted
into a second mounting portion disposed in the lower portion of the
cold air guide module.
3. The refrigerator according to claim 1, wherein the first and
second sensors are coupled at diagonal points on a rectangular
portion of a plane formed by a back surface of the ice tray.
4. The refrigerator according to claim 1, wherein the cold air is
supplied into the cooling space through a discharge duct, and the
cold air guide module extends from at least one surface of the
discharge duct.
5. The refrigerator according to claim 4, wherein the cold air
guide module comprises: a first cold air guide member extending
from an upper surface of the discharge duct; and a second cold air
guide member extending from a lower surface of the discharge duct,
and wherein the second cold air guide member is spaced apart from a
back surface of the ice tray, wherein a cold air movement passage
is formed between the back surface of the ice tray and an upper
surface of the second cold air guide member.
6. The refrigerator according to claim 1, wherein the first sensor
is a light-emitting sensor and the second sensor is a
light-receiving sensor.
7. A method of manufacturing an ice maker for a refrigerator, the
method comprising: manufacturing an ice making assembly, an ice
bucket, and a transfer assembly forming an ice maker; coupling a
first sensor of a full ice detection module to a lower portion of a
rotation module of the ice making assembly; coupling a second
sensor of the full ice detection module to a lower portion of a
cold air guide module of the ice making assembly, wherein the full
ice detection module is configured for detecting whether the ice
bucket is full; adjusting a position of the first sensor coupled to
the rotation module and a position of the second sensor coupled to
the cold air guide module, wherein the first sensor is operatively
coupled to the second sensor; and assembling the transfer assembly
to a side of the ice bucket and assembling the ice making assembly
to an upper side of the ice bucket.
8. The method according to claim 7, further comprising: disposing
an ice tray at an upper side of the cold air guide module; and
coupling the first and second sensors at diagonal points on a
rectangular portion of a plane formed by a back surface of the ice
tray.
9. An apparatus comprising: an ice maker comprising: a main body
having a cooling space for receiving cold air generated by a
cooling module; an ice making assembly comprising: an ice tray
disposed in the cooling space to generate ice, a cold air guide
module disposed at a lower side of the ice tray and configured to
guide the cold air supplied from the cooling module to the lower
side of the ice tray; and a rotation module configured for rotating
at least one of the ice tray and an ejector for ejecting the ice
from the ice tray; an ice bucket disposed at a lower side of the
ice making assembly to receive ice from the ice tray; and a full
ice detection module comprising a first sensor coupled to a lower
portion of the rotation module and a second sensor coupled to a
lower portion of the cold air guide module, and detecting whether
or not the ice bucket is full by operative interconnection of the
first and second sensors.
10. The apparatus according to claim 9, wherein the first sensor is
inserted into a first mounting portion disposed in the lower
portion of the rotation module and the second sensor is inserted
into a second mounting portion disposed in the lower portion of the
cold air guide module.
11. The apparatus according to claim 9, wherein the first and
second sensors are coupled at diagonal points on a rectangular
portion of a plane formed by a back surface of the ice tray.
12. The apparatus according to claim 9, wherein the cold air is
supplied into the cooling space through a discharge duct, and the
cold air guide module extends from at least one surface of the
discharge duct.
13. The apparatus according to claim 4, wherein the cold air guide
module comprises: a first cold air guide member extending from an
upper surface of the discharge duct; and a second cold air guide
member extending from a lower surface of the discharge duct, and
wherein the second cold air guide member is spaced apart from a
back surface of the ice tray, wherein a cold air movement passage
is formed between the back surface of the ice tray and an upper
surface of the second cold air guide member.
14. The apparatus according to claim 9, wherein the first sensor is
a light-emitting sensor and the second sensor is a light-receiving
sensor.
Description
RELATED APPLICATION
[0001] This application claims priority to Korean Patent
Application No. 10-2015-0086161, filed Jun. 17, 2015, hereby
incorporated by reference in its entirety.
FIELD
[0002] Embodiments of the present invention generally relate to a
refrigerator and a method of manufacturing an ice maker
therefor.
BACKGROUND
[0003] A refrigerator is an appliance for storing food at low
temperature, and may store food in a frozen or refrigerated state
according to the type of food.
[0004] The interior of the refrigerator is cooled by continuously
supplied cold air, and the cold air is generated through heat
exchange with refrigerant by a refrigeration cycle performing a
compression-condensation-expansion-evaporation process. The cold
air supplied into the refrigerator is evenly transferred to the
interior of the refrigerator by convection and thus the food in the
refrigerator may be maintained at a desired temperature.
[0005] The refrigerator typically has a rectangular main body which
is open at a front surface thereof. The main body may have a
refrigerating chamber and a freezing chamber therein. The front
surface of the main body may be disposed with a refrigerating
chamber door and a freezing chamber door, for selectively opening a
portion of the refrigerator. The refrigerator may include a
plurality of drawers, shelves, and storage boxes, etc., in order to
optimally store various foods in an internal storage space of the
refrigerator.
[0006] Conventionally, a top-mount type refrigerator, in which a
freezing chamber is located in the upper portion and a
refrigerating chamber is located in the lower portion, has been
used. In recent years, a bottom-freezer type refrigerator, in which
a freezing chamber is located in the lower portion, has been also
developed in order to increase user convenience.
[0007] The bottom-freezer type refrigerator has an advantage in
that it is convenient for a user to frequently utilize a
refrigerating chamber since it is located in the upper portion and
the relatively less used freezing chamber is located in the lower
portion. However, the bottom-freezer type refrigerator is
inconvenient for user access to ice in the freezing chamber because
the user has to bend over to access the freezing chamber.
[0008] In order to resolve this problem, another bottom-freezer
type refrigerator in which a dispenser for getting ice is disposed
in the refrigerating chamber door located at the upper portion of
the refrigerator has been recently developed. In this case, an ice
maker may be disposed in the refrigerating chamber door or within
the refrigerating chamber.
[0009] The ice maker may include an ice making assembly which
generates ice and includes an ice tray, an ice bucket which stores
the generated ice, and a transfer assembly which transfers the ice
stored in the ice bucket to a dispenser.
[0010] Specifically, the ice made by the ice making assembly may be
dropped, into and be collected in, the ice bucket located beneath
the ice tray. The conventional ice maker includes a detection
lever, a sensor, or the like capable of detecting whether or not
the amount of ice collected in the ice bucket exceeds a
predetermined amount. The ice maker may be controlled such that the
ice maker is stopped when the amount of ice exceeds the
predetermined amount.
[0011] However, since the conventional detection lever (or sensor)
has a very limited ability to detect ice, there is a problem in
that the amount of ice collected in the ice bucket is not
accurately detected.
[0012] In addition, the sensor is mounted to the ice maker equipped
with a plurality of components in a small space, and the ice maker
is complicated to manufacture.
SUMMARY
[0013] Therefore, embodiments of the present invention address and
solve the above problems, and it is an object of the present
invention to provide a refrigerator including an ice maker capable
of accurately detecting whether or not an ice bucket is full of
ice.
[0014] It is another object of the present invention to provide a
method of manufacturing an ice maker for a refrigerator, in which a
full ice detection module is readily mounted to the ice maker.
[0015] According to an embodiment, what is described is a
refrigerator comprising: a case having a food storage space; a
cooling module configured for generating cold air and comprising a
compressor, a condenser, an expansion valve, and an evaporator; a
door disposed on the case to shield the food storage space; and an
ice maker disposed in at least one of the food storage space and
the door, wherein the ice maker comprises: a main body having a
cooling space supplied with the cold air generated by the cooling
module; an ice making assembly comprising an ice tray arranged in
the cooling space to generate ice, a cold air guide section
disposed at a lower side of the ice tray and configured to guide
the cold air supplied from the cooling module to the lower side of
the ice tray, and a rotation module configured for rotating at
least one of the ice tray and an ejector for ejecting the ice from
the ice tray; an ice bucket disposed at a lower portion of the ice
making assembly and configured to receive the ice (e.g., dropped)
from the ice tray; and a full ice detection module comprising a
first sensor mounted to a lower portion of the rotation module and
a second sensor mounted to a lower portion of the cold air guide
module, and detecting whether or not the ice bucket is full of ice
by optical and/or operative interconnection of the first and second
sensors.
[0016] Further, wherein the first sensor is inserted into a first
mounting portion disposed in the lower portion of the rotation
module, and the second sensor is inserted into a second mounting
portion disposed in the lower portion of the cold air guide
section.
[0017] Further, wherein the first and second sensors are mounted at
diagonal points on a rectangular portion of a plane formed by a
back surface of the ice tray.
[0018] Further, wherein the cold air is supplied into the cooling
space through a discharge duct, and the cold air guide module
extends from at least one surface of the discharge duct.
[0019] Further, wherein the cold air guide module comprises: a
first cold air guide member extending from an upper surface of the
discharge duct; and a second cold air guide member extending from a
lower surface of the discharge duct, and wherein the second cold
air guide member is spaced apart from a back surface of the ice
tray, so that a cold air movement passage is formed between the
back surface of the ice tray and an upper surface of the second
cold air guide member.
[0020] Further, wherein, the first sensor is a light-emitting
sensor and the second sensor is a light-receiving sensor.
[0021] According to an embodiment, what is described is a method of
manufacturing an ice maker for a refrigerator, comprising:
manufacturing an ice maker comprising an ice making assembly, an
ice bucket, and a transfer assembly; mounting a first sensor of a
full ice detection module for detecting whether the ice bucket is
full of ice, to a lower portion of a rotation module of the ice
making assembly, and mounting a second sensor of the full ice
detection module to a lower portion of a cold air guide module of
the ice making assembly; adjusting a position of the first sensor
mounted to the rotation module and a position of the second sensor
mounted to the cold air guide module, wherein the first sensor is
optically and/or operatively coupled to the second sensor; and
assembling the transfer assembly to one side of the ice bucket and
assembling the ice making assembly to an upper side of the ice
bucket.
[0022] Further, wherein, an ice tray for accommodation of water or
ice is disposed at an upper side of the cold air guide module; and
the first and second sensors are mounted at diagonal points of a
rectangular portion of a plane formed by a back surface of the ice
tray.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The above and other objects, features and other advantages
of the present invention will be more clearly understood from the
following detailed description taken in conjunction with the
accompanying drawings, in which:
[0024] FIG. 1 is a view illustrating a refrigerator according to an
embodiment of the present invention;
[0025] FIG. 2 is a side cross-sectional view illustrating an ice
maker in FIG. 1;
[0026] FIG. 3 is an exploded perspective view illustrating the ice
maker in FIG. 2;
[0027] FIG. 4 is a planar cross-sectional view conceptually
illustrating the ice maker in FIG. 2; and
[0028] FIG. 5 is an exemplary flowchart illustrating an exemplary
method of manufacturing the ice maker according to an embodiment of
the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0029] Exemplary embodiments of the present invention will be
described below in detail with reference to the accompanying
drawings. In certain embodiments, detailed descriptions of relevant
constructions or functions well known in the art may be omitted to
avoid obscuring appreciation of the disclosure.
[0030] FIG. 1 is a view illustrating a refrigerator according to an
embodiment of the present invention. FIG. 2 is a side
cross-sectional view illustrating an ice maker in FIG. 1. FIG. 3 is
an exploded perspective view illustrating the ice maker in FIG.
2.
[0031] Referring to FIGS. 1 to 3, the refrigerator 1 according to
the embodiment may include a case 2 defining an external structure
and/or appearance thereof, a barrier which divides a food storage
space and partitions the case 2 into an upper refrigerating chamber
R and a lower freezing chamber F, refrigerating chamber doors 3
disposed at both front edges of the case 2 to selectively open and
close the refrigerating chamber R by rotation thereof, and a
freezing chamber door 5 which functions as a front opening portion
of the freezing chamber F. Although an ice maker 10 is illustrated
as being disposed at one side of an upper portion of the
refrigerating chamber R in the embodiment, this is by way of
example only. Alternatively, the ice maker 10 may be installed at a
different position in the refrigerating chamber R or in a different
place such as the refrigerating chamber door 3.
[0032] The ice maker 10 disposed in the refrigerator 1 is capable
of detecting whether or not an ice bucket 320 is full of ice. The
ice maker 10 may include a main body 100, a cooling section (not
shown), an ice making assembly 200, an ice bucket 320, a transfer
assembly 400, and a full ice detection module 500.
[0033] The main body 100 of the ice maker 10 has a cooling space
105 in which ice may be generated. The ice making assembly 200 is
disposed at an upper side in the cooling space 105 and the ice
bucket 320 may be arranged at a lower side of the ice making
assembly 200.
[0034] The cooling module functions to generate cold air and supply
the cold air to an ice tray 210. The cooling module includes a
compressor, a condenser, an expansion valve, an evaporator, etc.
which perform a cooling cycle. The cooling module generates cold
air by exchanging heat between a refrigerant and air as is well
known. Cold air may be supplied to the ice tray 210 through a
discharge duct 310 and a cold air guide module 220 by a blower or
the like.
[0035] The ice making assembly 200 includes an ice tray 210 which
receives water, a cold air guide module 220 which guides the flow
of cold air such that the cold air supplied from the cooling module
moves along a back surface of the ice tray 210, and a rotation
module 230 which rotates the ice tray 210 to drop the ice into the
ice bucket 320.
[0036] The ice tray 210 provides a space in which water supplied
from a water supply pipe (not shown) or the like is cooled to
produce ice, and has a plurality of ice forming spaces formed on an
upper surface thereof to accommodate water. The forming spaces may
have various shapes according to the shape of ice to be made, and
the number of forming spaces may vary.
[0037] The ice tray 210 may be made of metal having high thermal
conductivity, e.g., aluminum. The ice tray 210 may improve a heat
exchange rate between water and cold air due to high thermal
conductivity. Consequently, the ice tray 210 serves as a type of
heat exchanger. Although not illustrated, the back surface of the
ice tray 210 may be provided with cooling ribs or the like for
increasing surface area contact with the cold air.
[0038] The cold air guide module 220 functions to guide the cold
air supplied from the cooling module to the lower side of the ice
tray 210. The cold air guide module 220 is coupled to the discharge
duct 310 to form a passage through which the cold air is supplied
from the cooling module. The cold air guide module 220 includes
cold air guide elements 221 and 222 coupled to at least one surface
of the discharge duct 310, and includes a first cold air guide
element 221 extending from an upper surface of the discharge duct
310 and a second cold air guide element 222 extending from a lower
surface of the discharge duct 310.
[0039] The first cold air guide element 221 is coupled between the
upper surface of the discharge duct 310 and a bracket 221 to which
the ice tray 210 is mounted. The second cold air guide element 222
extends from the lower surface of the discharge duct 310 and is
spaced apart from the back surface of the ice tray 210. Thus, a
cold air passage 225 for cold air flow is formed between the back
surface of the ice tray 210 and an upper surface of the second cold
air guide element 222.
[0040] The cold air guided by the cold air guide elements 221 and
222 flows toward the back surface of the ice tray 210, and
exchanges heat with the ice tray 210 so that the water present in
the ice tray 210 is transformed into ice.
[0041] The ice made in the above manner is dropped into the ice
bucket 320 disposed beneath the ice tray 210 by the rotation module
230. Specifically, the upper surface of the ice tray 210 may be
turned toward the ice bucket 320 by rotation of a rotary shaft 234,
and the ice tray 210 may be twisted (e.g., distorted) by contact
with a fixed element (not shown) when rotating beyond a specific
angle. Consequently, through the twisting of the ice tray 210, ice
in the ice tray 210 is dropped into the ice bucket 320.
[0042] In addition, a plurality of ejectors (not shown) may be
disposed in a longitudinal direction of the rotary shaft 234 so ice
is ejected from the ice tray 210 by rotation of the ejectors,
without the rotation of the ice tray 210. The rotary shaft 234 is
driven by an ice maker driving module 232, and the ice maker
driving module 232 is coupled in the ice making space 105 by an ice
maker fixture 233.
[0043] Moreover, the ice tray 210 may be equipped with a deicing
heater 231 which heats a surface of the ice tray 210 during or
before rotation of the rotary shaft 234. Ice is separated from the
ice tray 210 in a manner that melts the surface of the ice in the
ice tray 210 with heat from the deicing heater 231.
[0044] The transfer assembly 400 transfers ice toward an ice
discharge module 600, and may include an auger 410 and an auger
motor 420. The auger 410 is a rotatable element having blades in a
screw or spiral form, and is rotated by the auger motor 420. The
auger 410 is disposed in the ice bucket 320. Ice collected in the
ice bucket 320 may be inserted between the blades of the auger 410
to be transferred toward the ice discharge module 600 by rotation
of the auger 410. The auger motor 420 is disposed in an auger motor
housing 430.
[0045] The ice discharge module 600 is connected to a dispenser
(not shown) disposed in one of the refrigerating chamber doors 3,
and the ice transferred by the transfer assembly 400 is supplied to
a user through the dispenser according to an activation thereof by
the user. Although not illustrated, the ice discharge module 600
has a cutting element for cutting ice into a predetermined
size.
[0046] FIG. 4 is a planar cross-sectional view conceptually
illustrating the ice maker in FIG. 2.
[0047] Referring to FIG. 4, the full ice detection module 500
detects that ice is collected in the ice bucket 320 beyond a
certain extent, that is, detects whether the ice bucket 320 is full
of ice. The full ice detection module 500 includes a pair of first
and second sensors 510 and 520, which are mounted to the rotation
module 230 and the cold air guide section 220, respectively. The
sensors 510 and 520 may be photo sensors such as infrared sensors,
and may be configured as a light-emitting sensor and a
light-receiving sensor for instance.
[0048] The light-emitting sensor is a sensor configured for
emitting light which may be blocked by ice, and the light-receiving
sensor is a sensor configured for detecting light. When light
emitted from the light-emitting sensor is not received by the
light-receiving sensor, it may be determined that a blocking
material, namely ice, is present in a path of light. In an
exemplary embodiment, the first sensor 510 is a light-emitting
sensor and the second sensor 520 is a light-receiving sensor which
are described below.
[0049] The heights (e.g., y-axis coordinates) at which the first
and second sensors 510 and 520 of the full ice detection module 500
are mounted to the rotation module 230 and the cold air guide
module 220 vary according to the limited amount of ice which may be
accommodated in the ice bucket 320 (hereinafter, referred to as the
"predetermined limited capacity"). The first and second sensors 510
and 520 of the full ice detection module 500 are coupled to the
rotation module 230 and the cold air guide module 220 at the
relevant heights.
[0050] The first sensor 510 may be mounted to a lower portion of
the ice maker fixture 233 of the rotation module 230 located at one
side along the longitudinal direction (x-axis direction) of the ice
tray 210. The first sensor 510 may be mounted to the ice maker
fixture 233 through a first mounting portion 511 disposed in the
ice maker fixture 233. The first mounting portion 511 may have a
groove into which the first sensor 510 is inserted therein.
[0051] The second sensor 520 are coupled to the other side of the
lower portion of the second guide member 222 along the longitudinal
direction of the ice tray 210. The second sensor 520 is coupled to
the second guide member 222 through a second mounting portion 521
disposed in the second guide member 222. The second mounting
portion 521 may have a groove into which the second sensor 520 is
inserted therein.
[0052] Although the structures in which the first sensor 510 is
coupled to the rotation member 230 and the second sensor 520 is
coupled to the cold air guide section 220 have been described with
respect to the above described embodiment, the positions of the
first and second sensors 510 and 520 may be reversed.
[0053] The first and second sensors 510 and 520 are mounted at
diagonal points on a rectangular portion of a plane (e.g., x-z
plane) formed by the back surface of the ice tray 210. That is, the
first and second sensors 510 and 520 are mounted at different
points on the z-axis. For example, a distance between the first and
second sensors 510 and 520 in the z-axis direction may correspond
to the width (e.g., z-axis length) of the cold air guide module
220.
[0054] Hereinafter, the operation and results or functions of the
ice maker 10 according to the embodiment of the present invention
will be described.
[0055] In the ice maker 10 according to an embodiment, cold air
generated through the compressor, the condenser, the expansion
valve, and the evaporator is supplied to the cooling space 105 via
the discharge duct 310. The cold air freezes water placed in the
ice tray 210 disposed in the cooling space 105. In this case, since
the cold air guide module 220 is connected to the discharge duct
310 and extending therefrom, the cold air discharged from the
discharge duct 310 moves along the cold air guide module 220.
[0056] Referring to FIG. 2, the cold air enters between the first
cold air guide element 221 and the second cold air guide element
222 and then moves along the cold air passage 225 formed between
the back surface of the ice tray 210 and the second guide element
222. The cold air exchanges heat with the back surface of the ice
tray 210 while moving along the back surface of the ice tray 210,
and cools water in the ice tray 210 so as to form ice. The ice made
in the ice tray 210 is dropped downward by rotation of the rotary
shaft 234 and may be collected in the ice bucket 320 arranged
beneath the ice tray 210.
[0057] As ice is generated, the amount of ice collected in the ice
bucket 320 may exceed a predetermined limited capacity of the ice
bucket 320. In this case, the full ice detection module 500 detects
whether or not the amount of ice collected in the ice bucket 320
exceeds the predetermined limited capacity of the ice bucket
320.
[0058] The first sensor 510 may constantly or periodically emit
light, and the light emitted from the first sensor 510 reaches the
second sensor 520 located on the diagonal path. When the light
passing through the diagonal path is received by the second sensor
520, the amount of ice collected in the ice bucket 320 may be
determined to be less than the predetermined limited capacity of
the ice bucket 320.
[0059] When ice is accumulates in the ice bucket 320 and exceeds a
predetermined height, e.g., to the detection height of the full ice
detection module 500, light emitted from the first sensor 510 hits
the ice and the light is not received by the second sensor 520.
Accordingly, a control unit (not shown) determines whether the ice
bucket 320 is full of ice. Then, the control unit stops the driving
of the rotation module 230 and stops and/or pauses the operation of
the components for manufacturing ice.
[0060] In the ice maker 10 according to an embodiment, when the
full ice detection section 500 is disposed on the back surface of
the cold air guide module 220, the lower region of the ice tray 210
overlaps with the lower region of the cold air guide module 220.
Therefore, the full ice detection section 500 may effectively
detect the ice dropped from the ice tray 210.
[0061] In addition, since the first and second sensors 510 and 520
of the full ice detection section 500 are disposed at the diagonal
points in the ice tray 210, a detection region for ice detection is
enlarged as compared to a case where the first and second sensors
510 and 520 of the full ice detection section 500 are mounted in a
linear section.
[0062] Moreover, since a mechanical full ice detection structure
such as a detection lever is replaced with the full ice detection
module 500 according to the embodiment, the number of parts and
assembly processes may be reduced and thus manufacturing costs are
reduced.
[0063] Furthermore, since the detection region for detecting
whether the ice bucket is full of ice is enlarged, factors
contributing to malfunction due to full ice detection errors are
reduced, and thus the ice maker has improved reliability.
[0064] Hereinafter, a method of manufacturing the ice maker
according to an embodiment of the present invention will be
described.
[0065] FIG. 5 is a flowchart illustrating an exemplary method of
manufacturing the ice maker according to an embodiment of the
present invention.
[0066] Referring to FIGS. 1 to 5, the above-mentioned ice maker 10
comprises the ice making assembly 200, the ice bucket 320, and the
transfer assembly 400. In order to manufacture the ice maker 10
according to an embodiment, the ice making assembly 200, the ice
bucket 320, and the transfer assembly 400, which constitute the ice
maker 10, are individually manufactured in the known manner (S100).
The first sensor 510 of the full ice detection module 500 for
detecting whether the ice bucket 320 is full of ice is mounted to
the lower portion of the rotation module 230 of the ice making
assembly 200, and the second sensor 520 of the full ice detection
section 500 is mounted to the lower portion of the cold air guide
module 220 of the ice making assembly 200 (S200).
[0067] In this case, the first and second sensors 510 and 520 are
mounted at the diagonal points on a rectangular portion of the
plane formed by the back surface of the ice tray 210. The position
of the first sensor 510 mounted to the rotation module 230 and the
position of the second sensor 520 mounted to the cold air guide
module 220 may be adjusted such that the first sensor 510 is
optically and/or operatively coupled to the second sensor 520
(S300). That is, the positions of the first and second sensors 510
and 520 may be adjusted such that light emitted from the first
sensor 510 is received by the second sensor 520.
[0068] When the position adjustment of the first and second sensors
510 and 520 is completed, the transfer assembly 400 is assembled to
one side of the ice bucket 320 and the ice making assembly 200 is
assembled to the upper side of the ice bucket 320 (S400). The ice
maker 10 manufacture may be completed by additionally assembling
the main body 100, the ice discharge module 600, etc., to form the
ice maker 10.
[0069] The first and second sensors 510 and 520 of the full ice
detection module 500 according to the embodiment are mounted to the
ice making assembly 200 and manufactured as a single assembly.
Thus, the full ice detection module 500 is mounted to the ice
making assembly 200 before the assemblies forming the ice maker 10
are assembled to each other. That is, since the full ice detection
section 500 components including the pair of sensors 510 and 520
and is mounted to the single assembly, the full ice detection
section 500 may be easily mounted without interference with the
other assemblies.
[0070] In addition, the process of adjusting the positions of the
first and second sensors 510 and 520 in order to optically and/or
operatively interconnect the first and second sensors 510 and 520
as light-emitting and light-receiving sensors may be easily
performed.
[0071] In accordance with exemplary embodiments of the present
invention, a refrigerator including an ice maker capable of
accurately detecting whether or not an ice bucket is full of ice is
provided.
[0072] In addition, a method of manufacturing the ice maker for the
refrigerator is provided, in which a full ice detection module is
easily mounted to the ice maker.
[0073] Although the preferred embodiments of the present invention
have been disclosed for illustrative purposes, it will be apparent
to those skilled in the art that various changes and modifications
can be made without departing from the spirit and scope of the
invention as defined in the following claims. More particularly,
various variations and modifications are possible in constituent
elements of the embodiments. In addition, it is to be understood
that differences relevant to the variations and modifications fall
within the spirit and scope of the present disclosure defined in
the appended claims.
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