U.S. patent application number 14/835560 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 | 20160370080 14/835560 |
Document ID | / |
Family ID | 57587864 |
Filed Date | 2016-12-22 |
United States Patent
Application |
20160370080 |
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 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; a transfer assembly configured
for transferring the ice collected in the ice bucket to an ice
discharge module; and a full ice detection module configured for
detecting whether the ice bucket is full of the ice. The full ice
detection module comprises: a first sensor mounted to the rotation
module configured to emit light; a reflective element coupled to
the transfer assembly and configured to reflect the light emitted
from the first sensor; and a second sensor coupled to the rotation
module and spaced apart from the first sensor by a predetermined
distance to allow detection of the light reflected by the
reflective element.
Inventors: |
YANG; Sung Jin; (Seoul,
KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Dongbu Daewoo Electronics Corporation |
Seoul |
|
KR |
|
|
Family ID: |
57587864 |
Appl. No.: |
14/835560 |
Filed: |
August 25, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F25C 5/187 20130101;
F25C 5/24 20180101 |
International
Class: |
F25C 5/18 20060101
F25C005/18; F25C 1/24 20060101 F25C001/24; F25C 5/06 20060101
F25C005/06; F25D 23/00 20060101 F25D023/00; F25D 17/04 20060101
F25D017/04; F25D 29/00 20060101 F25D029/00; F25C 5/00 20060101
F25C005/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 17, 2015 |
KR |
10-2015-0086163 |
Claims
1. A refrigerator comprising: a case comprising a food storage
space; a cooling module comprising a compressor, a condenser, an
expansion valve, and an evaporator and configured to generate cold
air; a door disposed on the case to shield 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; 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; a transfer assembly configured for
transferring the ice collected in the ice bucket to an ice
discharge module; and a full ice detection module configured for
detecting whether the ice bucket is full of the ice, and wherein
the full ice detection module comprises: a first sensor coupled to
the rotation module and configured to emit light; a reflective
element coupled to the transfer assembly and configured to reflect
the light emitted from the first sensor; and a second sensor
coupled to the rotation module, wherein the second sensor is spaced
apart from the first sensor by a predetermined distance to allow
detection of the light reflected by the reflective element.
2. The refrigerator according to claim 1, wherein the light emitted
from the first sensor is refracted through the reflective element
and is then received by the second sensor.
3. The refrigerator according to claim 1, wherein the ice making
assembly further comprises 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.
4. The refrigerator according to claim 1, wherein the first sensor
is inserted into a first mounting portion disposed in a lower
portion of the rotation module, and the second sensor is inserted
into a second mounting portion disposed in the lower portion of the
rotation module, wherein the second mounting portion being spaced
apart from the first mounting portion by a predetermined
distance.
5. The refrigerator according to claim 1, wherein the transfer
assembly comprises: an auger configured for transferring the ice;
an auger motor configured for driving the auger; and an auger motor
housing configured for coupling of the auger motor, and wherein the
reflective element is coupled to the auger motor housing.
6. The refrigerator according to claim 1, wherein the first sensor
and the reflective element are coupled at diagonal points on a
rectangular portion of a plane formed by a back surface of the ice
tray extending toward the transfer assembly.
7. The refrigerator according to claim 6, wherein the second sensor
and the reflective element are mounted at diagonal points on the
rectangular portion of the plane formed by the back surface of the
ice tray extending toward the transfer assembly.
8. The refrigerator according to claim 1, wherein the light emitted
from the first sensor moves along a zigzag path between the first
sensor, the reflective element, and the second sensor.
9. The refrigerator according to claim 1, wherein the reflective
element is detachably coupled to the transfer assembly by a third
mounting portion disposed in the transfer assembly.
10. The refrigerator according to claim 9, wherein the third
mounting portion comprises a slot into which the reflective element
can be slidably inserted.
11. 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 and a second sensor of a full ice detection module to a
rotation module of the ice making assembly; coupling a reflective
element of the full ice detection module to an auger motor housing
of the transfer assembly, wherein the full ice detection module is
configured for detecting whether the ice bucket is full of ice;
adjusting positions of the first and second sensors coupled to the
rotation module and a position of the reflective element coupled to
the auger motor housing to optically couple the first sensor, the
reflective element, and 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.
12. The method according to claim 11, wherein: the ice making
assembly comprises an ice tray disposed above the ice bucket; and
the first sensor, the reflective element, and the second sensor are
coupled in a zigzag arrangement at diagonal points on a rectangular
portion of a plane formed by a back surface of the ice tray
extending toward the transfer assembly.
13. The method according to claim 11, wherein the reflective
element is detachably coupled to the auger motor housing.
14. An apparatus for making ice, the apparatus comprising: a main
body having a cooling space configured 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; 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; a transfer assembly configured
for transferring the ice collected in the ice bucket to an ice
discharge module; and a full ice detection module configured for
detecting whether the ice bucket is full of the ice, wherein the
full ice detection module comprises: a first sensor coupled to the
rotation module and configured to emit light; a reflective element
coupled to the transfer assembly and configured to reflect the
light emitted from the first sensor; and a second sensor coupled to
the rotation module, wherein the second sensor disposed to allow
detection of the light reflected by the reflective element.
15. The refrigerator according to claim 14, wherein the light
emitted from the first sensor is refracted through the reflective
element and is then received by the second sensor.
16. The apparatus according to claim 14, wherein the ice making
assembly further comprises 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.
17. The apparatus according to claim 14, wherein the first sensor
is inserted into a first mounting portion disposed in a lower
portion of the rotation module, and the second sensor is inserted
into a second mounting portion disposed in the lower portion of the
rotation module, the second mounting portion being spaced apart
from the first mounting portion by a predetermined distance.
18. The apparatus according to claim 14, wherein the light emitted
from the first sensor moves along a zigzag path between the first
sensor, the reflective element, and the second sensor.
19. The apparatus according to claim 14, wherein the reflective
element is detachably coupled to the transfer assembly by a third
mounting portion disposed in the transfer assembly.
20. The apparatus according to claim 19, wherein the third mounting
portion has a slot into which the reflective element can be
slidably inserted.
Description
RELATED APPLICATION
[0001] This application claims priority to Korean Patent
Application No. 10-2015-0086163, 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 foods at low
temperature, and may store foods 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 foods 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. 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.
[0007] 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 for generating ice may be disposed in the refrigerating
chamber door or within the refrigerating chamber.
[0008] 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.
[0009] 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 operation of the ice
maker is stopped when the amount of ice exceeds the predetermined
amount.
[0010] 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.
[0011] In addition, since the sensor is mounted to the ice maker
equipped with a plurality of components in a small space, in that
the ice maker is complicated to manufacture.
SUMMARY
[0012] Therefore, the present invention has been made in view of
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.
[0013] 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 easily mounted to an ice maker.
[0014] According to an embodiment, 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 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 configured to receive the ice (e.g., dropped) from
the ice tray; a transfer assembly configured for transferring the
ice collected in the ice bucket to an ice discharge module; and a
full ice detection module configured for detecting whether or not
the ice bucket is full of the ice, and wherein the full ice
detection module comprises: a first sensor mounted to the rotation
module configured to emit light; a reflective element coupled to
the transfer assembly and configured to reflect the light emitted
from the first sensor; and a second sensor mounted to the rotation
module and spaced apart from the first sensor by a predetermined
distance to allow detection of the light reflected by the
reflective element.
[0015] Further, wherein the light emitted from the first sensor is
refracted through the reflective element and is then received by
the second sensor.
[0016] Further, wherein the ice making assembly further comprises a
cold air guide module provided at a lower side of the ice tray so
as to guide the cold air supplied from the cooling module to the
lower side of the ice tray.
[0017] Further, wherein the first sensor is inserted into a first
mounting portion disposed in a lower portion of the rotation
module, and the second sensor is inserted into a second mounting
portion disposed in the lower portion of the rotation module, the
second mounting portion being spaced apart from the first mounting
portion by a predetermined distance.
[0018] Further, wherein the transfer assembly comprises: an auger
for transferring the ice; an auger motor for driving the auger; and
an auger motor housing for accommodating the auger motor, and
wherein the reflective element is coupled to the auger motor
housing.
[0019] Further, wherein the first sensor and the reflective element
are mounted at diagonal points on a rectangular portion of a plane
formed by a back surface of the ice tray extending toward the
transfer assembly.
[0020] Further, wherein the second sensor and the reflective
element are mounted at diagonal points on the rectangular portion
of the plane formed by the back surface of the ice tray extending
toward the transfer assembly.
[0021] Further, wherein the light emitted from the first sensor
moves along a zigzag path between the first sensor, the reflective
element, and the second sensor.
[0022] Further, wherein the reflective element is detachably
mounted to the transfer assembly by a third mounting portion
disposed in the transfer assembly.
[0023] Further, wherein the third mounting portion has a slot into
which the reflective element is slidably inserted.
[0024] According to an embodiment, 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 and a second sensor of a full ice
detection module to a rotation module of the ice making assembly,
wherein the full ice detection module is configured for detecting
whether the ice bucket is full of ice, and mounting a reflective
element of the full ice detection module to an auger motor housing
of the transfer assembly; adjusting positions of the first and
second sensors mounted to the rotation module and a position of the
reflective element mounted to the auger motor housing such that the
first sensor, the reflective element, and the second sensor are
optically (e.g., operatively) coupled to each other; 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.
[0025] Further, the ice making assembly comprises an ice tray
arranged above the ice bucket; and the first sensor, the reflective
element, and the second sensor are mounted in a zigzag arrangement
at diagonal points of a rectangular portion of a plane formed by a
back surface of the ice tray extending toward the transfer
assembly.
[0026] Further, wherein the reflective element is detachably
coupled to the auger motor housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] 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:
[0028] FIG. 1 is a view illustrating an exemplary ice maker
disposed in a refrigerator according to an embodiment of the
present invention;
[0029] FIG. 2 is a side cross-sectional view illustrating the ice
maker in FIG. 1;
[0030] FIG. 3 is an exploded perspective view illustrating the ice
maker in FIG. 2;
[0031] FIG. 4 is a view illustrating a reflective element is
provided in an auger motor housing of the ice maker in FIG. 2;
[0032] FIG. 5 is a view for explaining the operation and function
of a full ice detection module of the ice maker in FIG. 4; and
[0033] FIG. 6 is a flowchart illustrating a method of manufacturing
the ice maker according to an embodiment of the present
invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0034] 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.
[0035] FIG. 1 is a view illustrating an exemplary ice maker
disposed in 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.
[0036] Referring to FIGS. 1 to 3, an ice maker 10 for a
refrigerator capable of detecting whether or not an ice bucket 320
is full of ice is shown. The ice maker 10 may include a main body
100, a cooling module (not shown), an ice making assembly 200, an
ice bucket 320, a transfer assembly 400, and a full ice detection
module.
[0037] The refrigerator 1 according to the embodiment may include a
case 2 defining an external structure and/or appearance thereof, a
barrier 4 which divides a food storage space partitioning 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 the ice maker 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.
[0038] The main body 100 of the ice maker 10 may have a cooling
space 105 in which ice may be generated. The ice making assembly
200 may be 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. The cooling module functions to generate cold
air and supply the generated cold air to an ice tray 210. The
cooling module may include a compressor, a condenser, an expansion
valve, an evaporator, etc. which performs a cooling cycle. The
cooling module generates cold air by exchanging heat between a
refrigerant and air. 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.
[0039] 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.
[0040] 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 be vary.
[0041] 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 having a high
thermal conductivity. Consequently, the ice tray 210 may serve 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.
[0042] Meanwhile, 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 may be coupled to
the discharge duct 310 as a passage through which the cold air is
supplied from the cooling module. The cold air guide module 220 may
include cold air guide elements 221 and 222 coupled to at least one
surface of the discharge duct 310, and may include 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.
[0043] The first cold air guide element 221 may be 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 may extend from the lower surface of the discharge duct
310 and be spaced apart from the back surface of the ice tray 210.
Thus, a cold air passage 225 for cold air flow may be formed
between the back surface of the ice tray 210 and an upper surface
of the second cold air guide element 222.
[0044] The cold air guided by the cold air guide elements 221 and
222 may flow toward the back surface of the ice tray 210, and may
exchange heat with the ice tray 210 so that the water present in
the ice tray 210 is transformed into ice.
[0045] The ice made in the above manner may be 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 may be dropped into the ice bucket 320.
[0046] In addition, a plurality of ejectors (not shown) may be
disposed in 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.
[0047] The rotary shaft 234 may be driven by an ice maker driving
module 232, and the ice maker driving module 232 may be coupled in
the ice making space 105 by an ice maker fixture 233.
[0048] 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 may be 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.
[0049] 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 may be a rotatable element having blades
in a screw or spiral form, and is rotated by the auger motor 420.
The auger 410 may be 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 may be disposed in
an auger motor housing 430.
[0050] The ice discharge module 600 may be connected to a dispenser
(not shown) disposed in one of the refrigerating chamber doors 3,
and the ice transferred by the transfer assembly 400 may be
supplied to a user through the dispenser according to an activation
thereof by the user. Although not illustrated, the ice discharge
module 600 may have a cutting element for cutting ice into a
predetermined size.
[0051] FIG. 4 is a view illustrating a reflective element disposed
on the auger motor housing of the ice maker in FIG. 2. FIG. 5 is a
view for explaining the operation and effect of the full ice
detection module of the ice maker in FIG. 4.
[0052] Referring to FIGS. 4 and 5, the full ice detection module
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 may include a pair of first
and second sensors 510 and 520 and a reflective element 530, which
are mounted to the rotation module 230 and the auger motor housing
430, 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.
[0053] 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 where
are described below.
[0054] The heights (e.g., y-axis coordinates) at which the first
and second sensors 510 and 520 and the reflective element 530 of
the full ice detection module are mounted to the rotation module
230 and the auger motor housing 430 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 and the reflective element
530 of the full ice detection module may be coupled to the rotation
module 230 and the auger motor housing 430 at the relevant
heights.
[0055] The reflective element 530 may be include a reflective
material for reflecting light emitted from the first sensor 510,
and may be an element having a flat reflective surface in order to
provide uniform reflection. The light emitted from the first sensor
510 may be received by the second sensor 520 via the reflective
element 530.
[0056] The reflective elements 530 may be designed as illustrated
in FIG. 4, and there may also be multiple reflective elements. In
addition, the reflective element 530 may also be coupled to an
entire surface of the auger motor housing 430.
[0057] The light emitted from the first sensor 510 may sequentially
pass through the reflective element 530 and the second sensor 520
along a zigzag path (e.g., as shown by the dotted line in FIG.
5).
[0058] The first and second sensors 510 and 520 may be mounted to a
lower portion of the ice maker fixture 233 of the rotation module
230 in in which the first and second sensors 510 and 520 are spaced
apart from each other. The reflective element 530 may be mounted to
the auger motor housing 430. In this case, the first and second
sensors 510 and 520 may be mounted to the rotation module 230
through a first mounting portion 511 and a second mounting portion
(not shown) having respective grooves into which the first and
second sensors 510 and 520 are inserted therein.
[0059] The reflective element 530 may be coupled to the auger motor
housing 430, or may be detachably mounted through a third mounting
portion 531 disposed in the auger motor housing 430. The third
mounting portion 531 may have a slot into which the reflective
element 530 is slidably inserted, and the reflective element 530
may be fixed to the third mounting portion 531 by a supporting,
gripping, or friction fit piece 532.
[0060] The first sensor 510 and the reflective element 530 may be
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
extending toward the transfer assembly 400. In addition, the
reflective element 530 and the second sensor 520 may be mounted at
diagonal points the rectangular portion of in the plane (e.g., x-z
plane) formed by the back surface of the ice tray 210 extending
toward the transfer assembly 400. That is, the first and second
sensors 510 and 520 and the reflective element 530 may be mounted
at different points on the z-axis.
[0061] Hereinafter, the operation and results or functions of the
ice maker according to the embodiment of the present invention will
be described.
[0062] In the ice maker 10 according to an embodiment, cold air
generated through the compressor, the condenser, the expansion
valve, and the evaporator may be supplied to the cooling space 105
via the discharge duct 310. The cold air may freeze 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 may move along the cold air guide module
220.
[0063] Referring to FIG. 2, the cold air may enter between the
first guide element 221 and the second guide element 222 and may
then move 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 may
cool water in the ice tray 210 so as to form ice. The ice made in
the ice tray 210 may be dropped downward by rotation of the rotary
shaft 234 and may be collected in the ice bucket 320 arranged
beneath the ice tray 210.
[0064] 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 may detect
whether or not the amount of ice collected in the ice bucket 320
exceeds the predetermined limited capacity of the ice bucket
320.
[0065] Referring to FIG. 5, the first sensor 510 may constantly or
periodically emit light, and the light emitted from the first
sensor 510 reaches the reflective element 530 located on the
diagonal path. The light reaching the reflective element 530 is
reflected (e.g., and refracted) by the reflective element 530 and
is received by the second sensor 520 located on the diagonal path
in the opposite direction.
[0066] 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.
[0067] 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, 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) may determine whether the
ice bucket 320 is full of ice. Then, the control unit may stop the
driving of the rotation module 230 and may stop and/or pause the
operation of the components for manufacturing ice.
[0068] The reflective element 530 is disposed between the first and
second sensors 510 and 520, thereby enabling the path of light
emitted from the first sensor 510 to reach the second sensor.
Consequently, the region in which the full ice detection module can
detect whether the ice bucket is full of ice may be enlarged.
[0069] In addition, the range of the detection region may be
adjusted by adding additional reflective elements. Since the
detection region can be enlarged using one or more low-priced
reflective elements instead of a relatively expensive sensor,
thereby reducing manufacturing cost.
[0070] Moreover, when the reflective element 530 is located on the
auger motor housing 430, it may be possible to detect whether or
not ice is fully present in other portions of the auger 410 and the
like as well as in a lower region of the ice tray 210.
[0071] The full ice detection modules replaces a mechanical full
ice detection structure and thereby the number of parts and
assembly processes may be reduced and thus manufacturing costs may
be reduced.
[0072] Furthermore, since the detection region for detecting
whether the ice bucket is full of ice is enlarged, factors
contributing to malfunctions due to full ice detection errors may
be removed, and thus the ice maker may have improved
reliability.
[0073] Hereinafter, a method of manufacturing the ice maker
according to an embodiment of the present invention will be
described.
[0074] FIG. 6 is a flowchart illustrating an exemplary method of
manufacturing the ice maker according to an embodiment of the
present invention.
[0075] Referring to FIGS. 1 to 6, the above-mentioned ice maker 10
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 and
second sensors 510 and 520 of the full ice detection module for
detecting whether the ice bucket 320 is full of ice are mounted to
the rotation module 230 of the ice making assembly 200 and the
reflective element 530 is mounted to the auger motor housing 430 of
the transfer assembly 400 (S200).
[0076] In this case, the first sensor 510 may be inserted into a
groove of the first mounting portion 511, and the second sensor 520
may be inserted into the groove of the second mounting portion. The
reflective element 530 may be slidably inserted into the slot of
the third mounting portion 531.
[0077] The first sensor 510, the reflective element 530, and the
second sensor 520 may be mounted in a zigzag arrangement at the
diagonal points on a rectangular portion of a plane formed by the
back surface of the ice tray 210 extending toward the transfer
assembly 400. The positions of the first and second sensors 510 and
520 mounted to the rotation module 230 and the position of the
reflective element 530 mounted to the auger motor housing 430 may
be adjusted such that the first sensor 510, the reflective element
530, and the second sensor 520 are optically and/or operatively
coupled to each other (S300). That is, the positions of the first
sensor 510, the reflective element 530, and the second sensor 520
may be adjusted such that light emitted from the first sensor 510
is reflected (e.g., and refracted) by the reflective element 530
and is then received by the second sensor 520.
[0078] The position adjustment for optically and/or operatively
interconnecting the first sensor 510, the reflective element 530,
and the second sensor 520 may be simplified as the reflective
element 530 covers an entire surface of the auger motor housing 430
or the reflective element 530 has an increased reflective area.
[0079] When the position adjustment of the first sensor 510, the
reflective element 530, and the second sensor 520 is completed, the
transfer assembly 400 may be assembled to one side of the ice
bucket 320 and the ice making assembly 200 may be 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.
[0080] Since the first sensor 510, the reflective element 530, and
the second sensor 520 of the full ice detection module are mounted
to different assemblies, the region detected by the full ice
detection module may be enlarged to support different assemblies.
In addition, the positions at which the first sensor 510, the
reflective element 530, and the second sensor 520 are optically
and/or operatively coupled to each other may be configured such
that the reflective element 530 is separated from the third
mounting portion 531. After the positions of the first sensor 510,
the reflective element 530, and the second sensor 520 are set, the
reflective element 530 may be inserted into the third mounting
portion 531.
[0081] That is, since the reflective element 530 is detachably
mounted to the auger motor housing 430, the operation for optical
and/or operatively coupled the first sensor 510, the reflective
element 530, and the second sensor 520 may be easily performed even
though the reflective element 530 is coupled to a separate assembly
from the first and second sensors 510 and 520.
[0082] In accordance with exemplary embodiments of the present
invention, it may be possible to provide a refrigerator including
an ice maker capable of accurately detecting whether or not an ice
bucket is full of ice.
[0083] In addition, it may be possible to provide a method of
manufacturing the ice maker for the refrigerator, in which a full
ice detection module is easily mounted to the ice maker.
[0084] 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
may 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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