U.S. patent application number 16/093390 was filed with the patent office on 2019-04-25 for clear ice making appliance and method of same.
The applicant listed for this patent is Whirlpool Corporation. Invention is credited to Arivazhagan CHANDRASHEKARAN, Jerry VISIN.
Application Number | 20190120534 16/093390 |
Document ID | / |
Family ID | 60038024 |
Filed Date | 2019-04-25 |
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United States Patent
Application |
20190120534 |
Kind Code |
A1 |
CHANDRASHEKARAN; Arivazhagan ;
et al. |
April 25, 2019 |
CLEAR ICE MAKING APPLIANCE AND METHOD OF SAME
Abstract
An aspect of the present disclosure is generally directed to an
ice making appliance that includes: an ice making compartment and
an ice maker including an ice mold having a total water capacity.
The ice mold includes a plurality of ice wells and is configured to
release the ice cubes without the use of a heater and by twisting
the ice mold. The ice wells are typically no more than about 12.2
mm in depth from a top surface of the ice mold and have a volume of
about 20 mL or less. The ice maker is capable of producing at least
about 3.5 lbs. of ice or more in a 24 hour span.
Inventors: |
CHANDRASHEKARAN; Arivazhagan;
(Issaquah, WA) ; VISIN; Jerry; (Benton Harbor,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Whirlpool Corporation |
Benton Harbor |
MI |
US |
|
|
Family ID: |
60038024 |
Appl. No.: |
16/093390 |
Filed: |
April 13, 2017 |
PCT Filed: |
April 13, 2017 |
PCT NO: |
PCT/US17/27379 |
371 Date: |
October 12, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62322157 |
Apr 13, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F25B 2700/173 20130101;
F25C 2700/12 20130101; F25C 2305/022 20130101; F25D 23/04 20130101;
Y02P 60/855 20151101; F25C 1/10 20130101; F25D 2317/063 20130101;
F25C 1/20 20130101; F25C 5/08 20130101; F25C 5/06 20130101; F25C
2500/06 20130101; Y02P 60/85 20151101; F25C 2500/02 20130101; F25D
11/02 20130101; F25C 2400/10 20130101; F25D 17/065 20130101; F25D
2400/02 20130101; F25D 2317/061 20130101; F25C 5/22 20180101; F25C
1/24 20130101 |
International
Class: |
F25C 1/20 20060101
F25C001/20; F25C 1/10 20060101 F25C001/10; F25C 1/24 20060101
F25C001/24; F25C 5/06 20060101 F25C005/06; F25C 5/08 20060101
F25C005/08; F25C 5/20 20060101 F25C005/20 |
Claims
1. A refrigerator comprising: an ice making compartment; an
icemaker located in the ice making compartment and comprising an
ice mold having a total water capacity; a motor disposed in the
icemaker and operably coupled to a first end of the ice mold; a
stop disposed on an end of the icemaker distal from the motor and
configured to prevent rotation of a second end of the ice mold
during harvesting; a water inlet disposed in the ice making
compartment and in fluid communication with the ice mold; a mineral
filter to provide substantially de-ionized water; wherein the ice
mold comprises a plurality of ice wells; wherein the ice mold is
configured to release the ice cubes without the use of a heater and
by twisting the ice mold; wherein the ice wells are no more than
about 12.2 mm in depth from a top surface of the ice mold; wherein
a volume of the ice wells are about 20 mL or less; and wherein the
icemaker is capable of producing at least about 3.5 lbs. of ice or
more in a 24 hour span.
2. The refrigerator of claim 1, wherein the hardness of the water
entering the ice mold is from about 0 to about 25 ppm.
3. The refrigerator of claim 2, wherein the icemaker is capable of
producing at least about 3.5 lbs. of ice or more in a 24 hour
span.
4. The refrigerator of claim 3, wherein the ice mold comprises up
to 10 ice wells.
5. The refrigerator of claim 4, wherein the ice wells measure about
23 mm on a side at the bottom surface of the ice mold and is at
least substantially square.
6. The refrigerator of claim 1, wherein the ice wells each further
comprise a bottom surface and a heat sink on an underside of the
ice wells.
7. The refrigerator of claim 6, wherein each heat sink comprises a
plurality of heat sink fingers extending downwardly and away from
the bottom surface of the ice wells.
8. The refrigerator of claim 7, wherein the heat sink fingers are
about 2 mm thick.
9. The refrigerator of claim 6, wherein the heat sink further
comprises a heat sink base.
10. The refrigerator of claim 9, wherein the heat sink base is
about 0.6 mm in thickness.
11. The refrigerator of claim 9, wherein the heat sink base further
comprises a cup wall in contact with the ice well.
12. A refrigeration appliance comprising: an ice making
compartment; an icemaker for forming ice cubes located in the ice
making compartment and comprising an ice mold having a total water
capacity; a motor disposed in the icemaker and operably coupled to
a first end of the ice mold; a stop disposed on an end of the
icemaker distal from the motor and configured to prevent rotation
of a second end of the ice mold during harvesting; a water inlet
disposed in the ice making compartment and in fluid communication
with a source of household water and the ice mold; a mineral filter
disposed between the source of household water and the water inlet
to provide substantially de-ionized water; wherein the ice mold
comprises a plurality of ice wells; wherein the ice mold is
configured to release the ice cubes by twisting the ice mold and
without the use of a heater; a heater disposed above the ice mold
and in electrical communication with a control; a thermistor in
electrical communication with the control positioned above the ice
mold; and a cold source that delivers cold air to the ice making
compartment whereby the heater causes the cold air traveling over
the ice mold to be warmer than the cold air traveling under the ice
mold and through the plurality of heat sinks engaged to the bottom
of each ice well of the ice mold.
13. The refrigeration appliance of claim 12, wherein the cold
source is an evaporator positioned in a freezer compartment of the
ice making appliance.
14. The refrigeration appliance of claim 12, wherein the cold
source is an evaporator and the ice making appliance further
comprises an adjustable speed air moving fan associated with the
evaporator that delivers the cold air to the ice making
compartment.
15. The refrigeration appliance of claim 14, wherein the adjustable
speed air moving fan is positioned within the ice making
compartment.
16. A method of forming clear ice in an icemaker disposed on a door
of a refrigerator comprising the steps of: providing an icemaker
with an ice mold having a perimeter and a plurality of ice wells
having a depth configured in at least two rows and at least two
columns, wherein the ice mold has a total water capacity; providing
weirs between the at least two rows of ice wells in a generally
centered position within each of the ice wells; providing weirs
between the at least two columns of ice wells at least
substantially adjacent the perimeter of the ice mold; filtering an
amount of seed fill by urging the seed fill through a mineral
filter disposed between a source of household water and a water
inlet disposed above the mold to provide substantially de-ionized
water; introducing an amount of seed fill of water into the ice
wells of the ice mold wherein the amount of seed fill of water is
substantially less than the total water capacity of the ice mold;
allowing the amount of seed fill of water to freeze; adding a
remaining amount of water into the ice mold; and directionally
freezing the remaining amount of ice in the ice mold thereby
producing clear ice pieces.
17. The method of claim 16, wherein the ice mold total water
capacity is about 100 mL.
18. The method of claim 16, wherein the seed fill is 10-30% of the
total water capacity of the ice mold.
19. The method of claim 16, wherein the seed fill is about 20% of
the total water capacity of the ice mold.
20. The method of claim 16 further comprising the steps of:
rotating the ice mold clockwise at about 38 to about 42 degrees
from horizontal and thereafter pausing for at least about 3
seconds; rotating the ice mold counter-clockwise at about 38 to
about 42 degrees from horizontal and thereafter pausing for at
least about 3 seconds; and rotating the ice mold back to a
substantially horizontal position; wherein the step of rotating in
a counterclockwise direction and the step of rotating in a
clockwise direction can be done in either order.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a US National Phase application of and
claims benefit of and priority to PCT/US17/27379, filed on Apr. 13,
2017, entitled "CLEAR ICE MAKING APPLIANCE AND METHOD OF SAME."
PCT/US17/27379 claims priority to and the benefit of Provisional
U.S. Patent Application 62/322,157, entitled "CLEAR ICE MAKING
APPLIANCE AND METHOD OF SAME" filed Apr. 13, 2016, which are hereby
incorporated by reference in their entirety.
SUMMARY
[0002] An aspect of the present disclosure is generally directed to
an ice making appliance that includes: an ice making compartment;
an ice maker located in the ice making compartment and including an
ice mold having a total water capacity; a motor disposed in the ice
maker and operably coupled to a first end of the ice mold; a stop
disposed on an end of the ice maker distal from the motor and
configured to prevent rotation of a second end of the ice tray
during harvesting; a water inlet disposed in the ice making
compartment and in fluid communication with the ice mold. The ice
mold includes a plurality of ice wells and is configured to release
the ice cubes without the use of a heater and by twisting the ice
mold. The ice wells are typically no more than about 12.2 mm in
depth from a top surface of the ice mold and have a volume of about
20 mL or less. The ice maker is capable of producing at least about
3.5 lbs. of ice or more in a 24 hour span.
[0003] Another aspect of the present invention is generally
directed to a method of forming substantially clear ice that
includes the steps of: providing an ice maker within a refrigerated
appliance where the ice maker includes: an ice mold having a full
capacity including a plurality of ice wells; a motor operably
connected to the ice mold and capable of rotating the ice mold; and
a fill tube fluidly connected to a source of household water;
filling the ice mold with a seed fill of water which is about 20%
of the capacity of the ice mold; rotating the ice mold clockwise
from about 30 degrees to about 50 degrees from horizontal and
thereafter pausing for first period of time of at least about 3
seconds; rotating the ice mold counter-clockwise from about 30
degrees to about 50 degrees from horizontal and thereafter pausing
for a second period of time of at least about 3 seconds; rotating
the ice mold back to a substantially horizontal position; filling
the ice mold with water to the full capacity of the ice mold; and
freezing the water in the ice mold.
[0004] Still another aspect of the present disclosure is generally
directed toward an ice making appliance that includes: an ice
making compartment; an ice maker located in the ice making
compartment and including an ice mold having a total water
capacity; a motor disposed in the ice maker and operably coupled to
a first end of the ice mold; a stop disposed on an end of the ice
maker distal from the motor and configured to prevent rotation of a
second end of the ice tray during harvesting; a water inlet
disposed in the ice making compartment and in fluid communication
with the ice mold. The ice mold includes a plurality of ice wells.
The ice mold is configured to release the ice cubes by twisting the
ice mold and without the use of a heater. The ice making appliance
further typically includes a heater disposed above the ice mold and
in electrical communication with a control; a thermistor in
electrical communication with the control positioned above the ice
mold; and a cold source that delivers cold air to the ice making
compartment whereby the heater causes the cold air traveling over
the ice mold to be warmer than the cold air traveling under the ice
mold and through the plurality of heat sinks engaged to the bottom
of each ice well of the ice mold.
[0005] Another aspect of the present disclosure includes an ice
making appliance having: an ice making compartment; an ice maker
located in the ice making compartment and having an ice mold having
a total water capacity; a motor disposed in the ice maker and
operably coupled to a first end of the ice mold; a stop disposed on
an end of the ice maker distal from the motor and configured to
prevent rotation of a second end of the ice tray during harvesting;
and a water inlet disposed in the ice making compartment and in
fluid communication with the ice mold. The ice mold includes a
plurality of ice wells and a plurality of heat sinks with a heat
sink thermally engaged with a bottom of each ice well and having a
plurality of downwardly extending, planar heat sink fingers. The
ice mold is configured to release the ice cubes by twisting the ice
mold and without the use of a heater. The ice making appliance also
typically includes a heater disposed above the ice mold and in
electrical communication with a control; a thermistor in electrical
communication with the control positioned above the ice mold; a
cold source that delivers cold air to the ice making compartment
whereby the heater causes the cold air traveling over the ice mold
to be warmer than the cold air traveling under the ice mold and
through the plurality of heat sinks engaged to the bottom of each
ice well of the ice mold; and an air channeling bracket disposed
over the bottom of the ice tray and operably connected thereto
where the air channeling bracket has cold air inlets and air
outlets that are positioned to channel cold air from the cold
source through the air channeling bracket and through a plurality
of spaces between the downwardly extending fingers of the heat
sink.
[0006] These and other aspects, objects, and features of the
present invention will be understood and appreciated by those
skilled in the art upon studying the following specification,
claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] In the drawings:
[0008] FIG. 1 is an upper perspective view of a refrigerator as
disclosed.
[0009] FIG. 2A is a perspective view of a refrigerator as disclosed
with the fresh food doors open.
[0010] FIG. 2B is a front view of a refrigerator as disclosed with
the fresh food doors open.
[0011] FIG. 3A is a front view of a refrigerator as disclosed with
the icemaker in the drawer.
[0012] FIG. 3B is a front view of a refrigerator with the icemaker
in the freezer compartment.
[0013] FIG. 4A is a plan view comparison of a standard ice well and
an ice well as disclosed.
[0014] FIG. 4B is a side view comparison of a standard ice well
against the ice well as disclosed.
[0015] FIG. 5A shows air flow over standard ice wells.
[0016] FIG. 5B shows freezing regions of a standard ice well.
[0017] FIG. 5C shows cold air flow underneath the ice tray and air
flow at a temperature warmer than the freezing point of water blown
over the top of the ice tray as disclosed.
[0018] FIG. 5D shows freezing regions of the ice well as
disclosed.
[0019] FIG. 6A is a cross section of the ice tray shown in FIG. 6B
along line 6A-6A.
[0020] FIG. 6B is a perspective view of the ice tray of the
icemaker as disclosed.
[0021] FIG. 7A shows rocking motion of the ice tray in an
embodiment.
[0022] FIG. 7B shows another rocking motion of the ice tray in an
embodiment.
[0023] FIG. 8A is a plan view of a standard ice tray weir
configuration.
[0024] FIG. 8B shows a plan view of an ice tray with the weir
configuration of an embodiment.
[0025] FIG. 9A shows a single fill method of an embodiment.
[0026] FIG. 9B shows a multiple fill tube method of an
embodiment.
[0027] FIG. 9C shows a trough fill method of an embodiment.
[0028] FIG. 10 shows an isometric view of a heat sink of an
embodiment.
[0029] FIG. 11 is a cross section through the heat sink of an
embodiment.
[0030] FIG. 12 is a side view cross section of the ice tray with
heat sinks.
[0031] FIG. 13 is a front view of a cross section of an ice tray of
an embodiment.
[0032] FIG. 14 is an isometric view of heat sink of an
embodiment.
[0033] FIG. 15 shows a corner of the ice tray weir
configuration.
[0034] FIG. 16 is an exploded view of the icemaker of an
embodiment.
[0035] FIG. 17 shows a heater of an embodiment.
[0036] FIG. 18 shows a thermistor of an embodiment.
[0037] FIG. 19 shows a heater bracket and cover of an
embodiment.
[0038] FIG. 20 is an isometric view of an ice tray of an
embodiment.
[0039] FIG. 21 is an isometric view of a heat sink enclosure.
[0040] FIG. 22 is a duct connector of an embodiment.
[0041] FIG. 23 is a diagram of the duct work of an embodiment.
[0042] FIG. 24 is a cross section of the duct work of an
embodiment.
[0043] FIG. 25 is an isometric view of an icemaker of an
embodiment.
[0044] FIG. 26 is a diagram and chart showing clarity benefits.
[0045] FIG. 27 is a chart showing water hardness (in PPM) vs. the
clarity (on the Likert scale).
DETAILED DESCRIPTION
[0046] For purposes of description herein, the terms "upper,"
"lower," "right," "left," "rear," "front," "vertical,"
"horizontal," and derivatives thereof shall relate to the invention
as oriented in FIG. 1. However, it is to be understood that the
invention may assume various alternative orientations, except where
expressly specified to the contrary. It is also to be understood
that the specific devices and processes illustrated in the attached
drawings, and described in the following specification are simply
exemplary embodiments of the inventive concepts defined in the
appended claims. Hence, specific dimensions and other physical
characteristics relating to the embodiments disclosed herein are
not to be considered as limiting, unless the claims expressly state
otherwise.
[0047] FIG. 1 illustrates one embodiment of a refrigerator 10. The
refrigerator 10 includes a refrigerator housing or cabinet 12. Two
fresh food doors 18 provide access to a fresh food compartment 14.
While two doors are shown, it should be appreciated that only one
is needed for the present disclosure. A freezer door 20 provides
access to a freezer compartment 16. The refrigerator 10 is shown in
a bottom mount configuration where the freezer compartment 16 is
positioned below the fresh food compartment 14. An ice and water
dispenser 21 is positioned on one of the fresh food compartment
doors 18. Note that the ice and water dispenser 21 is positioned
remotely from the freezer compartment 16. While this particular
configuration of the refrigerator 10 is shown in FIG. 1, it should
be appreciated that other types of refrigerators may be used with
the present disclosure.
[0048] FIGS. 2A and 2B illustrate the refrigerator 10 of FIG. 1
with the fresh food doors 18 in an open position. With respect to
FIG. 2, an ice making compartment 22 is shown positioned within the
fresh food compartment 14, and adjacent one of the fresh food doors
18. FIG. 3 illustrates the refrigerator 10 of FIG. 1 with the fresh
food doors 18 in an open position wherein the ice making
compartment 22 is located on one of the fresh food doors 18. An ice
storage compartment 30 is provided adjacent to the ice making
compartment 22 on one of the fresh food doors 18. The ice storage
compartment may include a removable ice bucket 52 and the
compartment 30 is used to store formed ice cubes.
[0049] FIG. 3A illustrates a French-door bottom mount-type
refrigerator with refrigerated drawers. The refrigerator may have
the icemaker located in a drawer compartment 19 of the
refrigerator. FIG. 3B illustrates a similar-type refrigerator with
the icemaker located in the freezer compartment 16. It should be
noted that this may also be implemented in a French-door bottom
mount-type refrigerator without drawers 19.
[0050] FIGS. 4-6 show the differences in ice wells or ice cavities
42 in an ice tray 40 between 42a of the typical ice tray or mold 40
and the ice wells 42b of present disclosure. The ice tray 40 may
have a perimeter wall 28 (See FIG. 6B) configured to keep water
from spilling out of the ice tray 40, and a plurality of ice wells
42 formed in rows and columns as shown in FIG. 8B. The ice tray 40
as shown has 2 columns of 5 rows of wells, but it is understood
that any other configuration may be employed.
[0051] The ice wells 42b may have a larger surface area on the top
and the bottom of the ice well 42b as well as being of a shallower
depth. FIG. 4A shows a plan view of the ice wells 42. As shown in
FIG. 4A, ice well 42b is about 20-25 mm on both sides, more
preferably about 23 mm on each side, as compared with the typical
ice well which is about 18-20 mm on a side. The dimension h2 may be
about 10-15 mm, more preferably about 12.2 mm as shown as opposed
to the depth h1 of the current typical ice tray, which is about
20-25 mm, for a reduction of about 32% in height. This design
allows not only for clear ice which is directionally frozen from
the bottom of the ice cube to the top, but also a faster freezing
time, allowing for about 3.5-4.0 lbs of ice per day to be formed,
or about a 20-40% increase in ice production.
[0052] Since ice is an insulator, the decrease in cube height that
is formed by the ice wells 42b allows the heat to be transferred
from the top layers more efficiently. The larger cube base surface
area allows for more water to be exposed to the cold air under the
tray 40 and thus allowing for more efficient heat transfer from the
water to the passing air. This gained efficiency in heat transfer
within the cube itself improves the ice production rate of the
icemaker within a refrigerator 10.
[0053] FIGS. 5A and 5B show what happens in a typical ice well. As
shown in FIG. 5A, the ice well 42a, typically made of plastic or
metal, has cold air flow as shown by the arrows above and below the
ice well 42a. This air flow over the top of the water and
underneath the ice well 42a, allows the outer ring 46a of the water
to freeze first in the ice cube as shown in FIG. 5B. The first
layer to freeze 46a is an outer layer of the cube, followed by an
inner layer denoted by 46b, and finally the center of the ice cube
denoted 46c is frozen. This inward direction of freezing of the ice
cube 46 prevents the ice cube from being formed in a generally
clear formation.
[0054] The embodiment as shown by 5C and 5D allows the ice cube to
freeze in a generally upward direction from the bottom of the ice
cube to the top. As shown in FIG. 5C, cold air may be blown
underneath the ice tray 40, cooling the bottom side of the ice tray
40. The water within the ice tray 40 may cool and freeze first on
the bottom, and the ice cube may be cooled and frozen in a
generally upward direction from there. FIG. 5D shows this order of
freezing as the first layer 46a along the bottom of the cube, then
layer 46b, and finally 46c. It should be noted that the actual
freezing may not take place in distinct layers as shown, but rather
in a continuous fashion from bottom to top, but for ease of display
the direction of freezing was broken into distinct layers. In order
to keep the top of the ice cube from freezing, air at a temperature
warmer than the freezing point of water may be blown over the top
of the ice tray 40, as denoted by the arrows on the top of FIG. 5C.
However, it is important not to blow air that is too warm over the
top of the ice tray 40, as this has a detrimental effect on
freezing times.
[0055] In order to warm the air blowing over the top of the ice
tray 40, a heater assembly 70 may be employed. As detailed in FIG.
16, the heater assembly 70 may include a heater 72, which may be an
electric resistance heater or any other heater type known in the
art. The heater 72 may be disposed on a heater bracket 74, which
houses the heater 72 as well as a thermistor 78. The heater,
thermistor, and bracket are all covered by a bracket cover 76. The
heater and the thermistor are in electrical communication with a
controller (not shown) of the appliance. During ice formation, the
thermistor senses the temperature of the air being blown over the
top of the ice tray 40.
[0056] To create the ideal state for directional freezing the cold
(below 31.degree. F.) freezer air is directed across the bottom of
the tray. The top of the tray 40 may be kept at a temperature above
the freezing point of water(>32.degree. F.). To accomplish this
an active control is required to maintain the temperature. If the
temperature is too high the ice formation rate and energy usage is
negatively impacted. If the temperature is too low, it does not
allow for the directional cooling as described. This temperature is
preferably between about 37.degree. F. and about 43.degree. F. To
maintain this temperature range the heater 72 is used with feedback
temperature sensor or thermistor 78 to allow for heater control and
temperature monitoring. The heater 72 is incorporated into a cover
76 over the ice tray 40 isolating the top of the ice tray 40 from
the surrounding air allowing the icemaker to be stored in a
freezing environment. The temperature sensor 78 signals the control
to turn on the heater if temperature drops below a minimum set
point and then off as it rises above the maximum set point.
[0057] In another embodiment, heat may be added via an air duct,
damper, fan, and temperature sensor 78. This will again be a closed
loop temperature controlled system, but instead of using an
electric heater 72 it will use a damper and fan to direct air to
the top of the tray 40. The air supplied from within the
refrigerated compartment or similar area that is maintained above
the water freezing point. The damper may open if the temperature
drops below a given threshold and may close as it approaches the
upper temperature limit.
[0058] In another embodiment, waste heat from the electric motor 24
driving the ice tray is used during the freezing process described
above. The motor 24 may generate enough waste heat to maintain this
temperature, and a fan (not shown) may direct the waste heat above
the ice tray with a temperature sensor or thermistor 78 controlling
the fan operation based on minimum and maximum allowed
temperatures.
[0059] This directional freezing is crucial for production of clear
ice, as the impurities and air pockets within the cube are forced
to the top of the ice cube and may be released into the ambient air
within the ice making compartment, as opposed to being forced
toward the middle of the ice cube in a typical ice tray. The
impurities and air pockets are forced inward a due to the phase
change of the water to ice. The bottom surface area is crucial for
increasing the rate of production of ice in this system. The bottom
surface area for ice well 42b is about 28% greater than the current
typical ice well.
[0060] FIG. 6A-6B describe the filling process in more detail. A
seed fill may be used in the ice making process. A seed fill is a
small portion of the overall ice tray water capacity introduced
into the ice tray, before the ice tray 40 is filled in earnest.
This seed fill prevents a filled-to-capacity ice tray from super
cooling and preventing the directional freezing as described
below.
[0061] In a typical ice tray 40 there are weirs 48 between the sets
of ice wells 42. These weirs 48 distribute water between the ice
wells 42 such that the amount of water in each ice well 42 is
relatively even. These weirs 48 are typically not very deep, as
deep weirs add to the structural rigidity of the ice tray 40,
making removal of the ice from the ice tray 40 more difficult,
because it takes more force to twist the ice tray 40 to remove the
ice cubes from the ice tray 40. This also prevents an icemaker with
a single fill tube 50 from distributing a seed fill into the ice
tray without the use of multiple fill tubes 50.
[0062] By adding extra weirs 48a at the end of the ice wells, water
is allowed to flow more freely between the rows of ice wells as
opposed to just across the columns of ice wells 42. As described
herein the rows of ice wells are defined as those ice wells normal
to the axis of rotation, and the columns are the ice wells along
the axis of rotation. These weirs between the rows of ice cavities
may be closer to the ice tray perimeter 28, to allow the water to
flow more freely as it is rocked back and forth. These deeper weirs
48 allow a lower amount of seed fill water to be introduced to the
ice tray 40 and allow the seed fill to travel between the ice wells
in a generally even fashion. This configuration allows a seed fill
of about 20% of the total capacity of the ice tray, wherein without
this configuration a seed fill of less than about 50% may not be
able to traverse between ice wells to provide an even fill across
the ice wells 42.
[0063] Further, as shown by FIG. 7A-7B, during the seed fill the
tray 40 may be oscillated at a specific angle and frequency. A
motor 24 may be operably coupled with the ice tray 40 at one end of
the ice tray 40. The motor 24 may be in electrical communication
with a control (not shown) which may be microprocessor or a
microcontroller, or anything else known in the art. The angle and
frequency is determined by the water movement within the specific
tray 40 for efficient transfer of water from side to side to
promote the successful washing of water as the water freezes. It is
also based on the fill volume to prevent water from spilling over
the sides of the ice tray 40. This rotation aids in allowing
impurities within the water to escape and the water to freeze as
clear ice.
[0064] The tray may be rotated an angle of 30-50 degrees, more
preferably about 40 degrees clockwise and counterclockwise, in any
event not as far as to engage a stop 32 (see FIG. 25). As the tray
is rotated clockwise and counterclockwise, the tray may be held for
2-5 seconds to allow the water migration from cube to cube, more
preferably about 3 seconds. This rocking motion and method is
capable of distributing about 20 cubic centimeters of water across
the ten cubes as shown in the tray 40 substantially evenly, or
about 2 cubic centimeters per ice cube, with total ice cube volume
of about 10 cubic centimeters each. This rotation facilitates even
dispersement of the fill water within the ice mold 40 prior to
freezing.
[0065] FIGS. 8A and 8B show the weir configuration of typical ice
trays 40 as well as the new design. FIG. 8A shows the typical ice
tray 40 with weirs along the rows near the middle of the ice tray
40 and between the columns generally in the center of the ice
wells. FIG. 8B shows the ice weirs as disclosed with the weirs
between the rows generally in the center of the ice wells and the
weirs 48 between the columns near the outer edge of the ice tray
40. Because the weirs are located near the edge of the ice tray or
mold 40, the water may more easily traverse between the ice wells
42 during the rocking motion. This allows for more even
distribution as the ice tray 40 is rocked clockwise and
counterclockwise. Further, the location of the weirs near the walls
facilitates more flexibility, even though deeper weirs generally
make the tray 40 more rigid, because there is less plastic
connected to the side walls of the ice tray 40.
[0066] FIG. 9A-9C show three different methods of filling an ice
tray through a fill tube 50. FIG. 9A shows the fill as disclosed
with a single fill tube generally in the middle of the ice tray 40.
FIG. 9B shows a method of introducing fill evenly across all of the
ice wells by using multiple fill tubes from a single water inlet.
These fill tubes may be located at an end proximate the motor end
of the ice tray 40, one approximately in the center of the ice
mold, and another proximate the end distal from the motor. FIG. 9C
discloses another way of introducing multiple fill tubes by using a
trough with multiple points of entry into the ice tray 40. The
trough is generally downhill from the water supply to a distal end
of the ice tray 40. This allows the water to flow into the trough
in a generally downhill fashion from the near end of the water fill
to the far end of the trough.
[0067] FIGS. 10 and 11 generally show the addition of heat sinks 60
to the bottom of the ice wells 42. The heat sink 60 may be
comprised of one or more heat sinks fingers 62. These heat sinks
fingers 62 allow more efficient heat carrying capabilities to
remove the heat from the water in the ice well 42 into the air flow
below the ice wells that passes around and between the heat sink
fingers 62. The fingers 62 have a thickness (denoted by dimension C
in FIG. 11) and comprise a pair of substantially parallel planar
surfaces that extend in a generally downward direction from the
bottom of the heat sink base 64.
[0068] In FIG. 11 the thickness of the ice well 42 is denoted by
dimension A and is generally 0.6 to 1.0 millimeters, preferably 0.6
millimeters, and is at an angle .alpha., preferably about 20
degrees, from the perpendicular line coming out of the heat sink
base. Dimension B is generally 0.6 to 1.0 millimeters, preferably
0.6 millimeters. The thickness of the fingers 62 is denoted by
dimensions C and is generally 0.6 to 2 millimeters, preferably 2
millimeters. Dimension D the distance from the corner of the ice
well to the outermost fingers may be zero or anything greater than
zero millimeters.
[0069] FIG. 12-14 generally show the ice tray 40 with the heat
sinks 60 below each ice well 42. FIG. 12 shows the heat sink 60
further comprising a heat sink base 64 which attaches to the bottom
side of the ice well 42. The thickness of the heat sink base 64 may
be anywhere from 0.7 millimeters to 4.8 millimeters, preferably 0.7
millimeters. The lower the thickness of the heat sink base 64
allows for greater flexibility of the ice tray 40 during the
harvesting process.
[0070] The heat sinks may be integrated into the ice tray 40 by
overmolding the heat sinks within a plastic ice tray mold. The heat
sinks 60 may be placed into a plastic injection mold machine (not
shown) and located within the mold. A plastic material in liquid
form is then injected around the heat sinks 60 and allowed to cool.
This process integrates the heat sinks 60 and the plastic portion
of the ice tray 40 as if they were a single part. The heat sink
base 64 may mate with the bottom of the ice wells 42, or the heat
sink base may be used as the bottom of the ice well 42. In this
case, no plastic is injected over the top portion of the heat sink
base 64, and allows for more efficient heat exchange between the
heat sink 60 and the water within the ice tray 40.
[0071] FIG. 13 is a cross section through a center portion of the
ice tray 40 with the heat sinks 60 attached. The heat sink base 64
thickness is generally denoted by dimension A and is 0.7 to 4.8
millimeters, preferably 0.7 millimeters. Dimension B is a top
surface of the heat sink base 64 which is generally 15.6 by 17.2
millimeters. The heat sink base may also have a side wall that
generally conforms to the bottom of the side walls of the ice wells
43. Dimension C is the side wall angle of the heat sink base 64 and
is generally 19 degrees to 26 degrees, preferably about 20 degrees.
FIG. 14 generally shows the ice well 42 with the heat sink attached
and shows a preferred configuration with two cupped walls to allow
for a better flexing of the ice tray 40.
[0072] As shown in FIGS. 16-19, in the clear ice making process a
flexible tray is needed for making and harvesting the ice cubes. An
important aspect of the process is to evenly distribute the air
across all cubes, which is a 5.times.2 grid as shown, but may be
any configuration. This allows all cubes to freeze at the same
rate, front row and back row both get air. Without this piece the
air would follow the least resistant path and fall off before
traveling to the back row of cubes. Since the tray moves during ice
making and is required to rotate more than 160 degrees during
harvesting a stationary part is not achievable.
[0073] An air channel 80 as detailed in FIGS. 20-21 may be added to
and attached to the bottom of the twist ice tray 40 for maintaining
proper airflow across the tray bottom. This channel 80 may be made
from a flexible material, such as Santoprene.TM. or another
material known to have flexible properties at low temperatures,
such that it does not become rigid in freezing temperatures and
flexes without causing added torque from the motor 24 to twist the
full tray 40 and air channel 80. The attachment of air channel 80
to twist ice tray 40 may be achieved through attachments 82b on the
air channel 80 fit into attachment receivers 82a on the twist ice
tray 40. This attachment may also be accomplished by any other form
known in the art, such as with fasteners, clips, or the like. The
channel 80 captures air from an inlet duct at multiple angles and
promotes the airflow to completely travel the base of the ice tray
40. This keeps the ice quality the same for all cubes and helps
ensure all cubes freeze at substantially the same time.
[0074] As shown in FIG. 22-24, clear icemaker requires uniform
airflow across the entire width of the icemaker to make sure that
each cube is formed in the same time range. FIG. 23 specifically
describes an icemaking compartment 22 located in a drawer as shown
in FIG. 3A, although the descriptions could apply to other
locations within the fresh food compartment as well. Shown is an
inlet 84a at a source of cold air, usually a freezer compartment,
at one end of an inlet duct 84. The inlet duct terminates at an
inlet end 90a of a duct connector 90. The air travels through the
duct connector 90, out of the outlet end 90b of duct connector 90
to the ice maker, over or under the ice mold 40 as is desired, and
into an outlet duct 86. The outlet duct terminates in an outlet
86a, which may be located back at the source of cold air, or may be
located in another location where air warmer than that of the
source of cold air may be needed or desired.
[0075] The particular geometry of the air duct connector 90 in FIG.
22 may allow the airflow to be uniform across the icemaker. The
duct connector 90 may also direct the flow towards the bottom of
the icemaker, avoiding the air to go on top of the icemaker. The
duct 90 may direct the airflow so it is uniform across the icemaker
heat sinks. The duct 90 may also direct the airflow towards the
bottom of the ice mold 40 therefore avoiding cold air on top of the
icemaker by the inclination of the outlet end 90b of the duct
connector 90. The airflow uniformity is facilitated by the design
of dividers 92 inside the duct connector 90. The dividers 92 may
correct the airflow direction given by the ducts geometry between a
fan located in the freezer compartment evaporator (not shown) and
the icemaker. This is facilitated by the arcuate design of the
dividers 92, which divide the air which is generally constant
across the duct as it enters, and directs the air such that it
remains generally constant across the duct even as it traverses a
bend or corner.
[0076] As shown in FIG. 25, to harvest the ice within the ice tray
40 after the water has frozen into ice cubes, the tray 40 is
rotated about 150-170, preferably about 160 degrees, such that the
distal end 40 b of the ice tray 40 from the motor 24 abuts a stop
32. The motor 24 then continues to rotate the proximal end 40a of
the tray 40 about another 30 to 50 degrees, preferably about 40
degrees, imparting about a 40 degree twist in the tray. The twist
action causes the ice cubes to release from the tray and from each
other, and allows them to fall out due to the force of gravity.
This saves energy and is more efficient than an ice tray that
employs a separate heater or thermoelectric to cause a melt portion
of the ice cube to release it from the tray 40.
[0077] Shown in FIG. 27 is water hardness (in PPM) vs. the clarity
(on the Likert scale) of the ice produced. In order to improve the
clarity of the ice produced by the icemaker, it is advantageous to
de-ionize the water before it enters the ice tray 40. The
refrigerator may have a liquid filter (not shown) disposed in the
water line between the household water supply and the water fill
tube 50. The filter may be any form known in the art to filter out
unwanted particles from a flow of liquid. This filter may be a
mineral filter, which removes the ionization that occurs within the
water as it traverses water pipes. The hardness of the water is
measured in parts per million (PPM). The primary components of
water hardness are the ions of calcium (Ca 2+) and Magnesium (Mg
2+). The mineral filter acts to remove a substantial portion of
these ions from the water. As can be seen in the graph below, ice
cube clarity improves significantly once the water hardness drops
below about 100 PPM, and is best at about 0-20 PPM.
[0078] While all of the methods as described above provide
incremental improvements to the clarity of ice, a surprising effect
of employing multiple methods is shown in FIG. 26. As shown by the
chart, the combination of three of the four listed methods (A, B,
C, and D, defined in the Figure) improves the clarity of standard
ice cubes by 2.5-3.9 in combination. However, the addition of a
single fourth method to any of these combination of three results
in an improvement of another 2.5-3.9 on the Likert clarity
scale.
[0079] It will be understood by one having ordinary skill in the
art that construction of the described invention and other
components is not limited to any specific material. Other exemplary
embodiments of the invention disclosed herein may be formed from a
wide variety of materials, unless described otherwise herein.
[0080] For purposes of this disclosure, the term "coupled" (in all
of its forms, couple, coupling, coupled, etc.) generally means the
joining of two components (electrical or mechanical) directly or
indirectly to one another. Such joining may be stationary in nature
or movable in nature. Such joining may be achieved with the two
components (electrical or mechanical) and any additional
intermediate members being integrally formed as a single unitary
body with one another or with the two components. Such joining may
be permanent in nature or may be removable or releasable in nature
unless otherwise stated.
[0081] It is also important to note that the construction and
arrangement of the elements of the invention as shown in the
exemplary embodiments is illustrative only. Although only a few
embodiments of the present innovations have been described in
detail in this disclosure, those skilled in the art who review this
disclosure will readily appreciate that many modifications are
possible (e.g., variations in sizes, dimensions, structures, shapes
and proportions of the various elements, values of parameters,
mounting arrangements, use of materials, colors, orientations,
etc.) without materially departing from the novel teachings and
advantages of the subject matter recited. For example, elements
shown as integrally formed may be constructed of multiple parts or
elements shown as multiple parts may be integrally formed, the
operation of the interfaces may be reversed or otherwise varied,
the length or width of the structures and/or members or connector
or other elements of the system may be varied, the nature or number
of adjustment positions provided between the elements may be
varied. It should be noted that the elements and/or assemblies of
the system may be constructed from any of a wide variety of
materials that provide sufficient strength or durability, in any of
a wide variety of colors, textures, and combinations. Accordingly,
all such modifications are intended to be included within the scope
of the present innovations. Other substitutions, modifications,
changes, and omissions may be made in the design, operating
conditions, and arrangement of the desired and other exemplary
embodiments without departing from the spirit of the present
innovations.
[0082] It will be understood that any described processes or steps
within described processes may be combined with other disclosed
processes or steps to form structures within the scope of the
present invention. The exemplary structures and processes disclosed
herein are for illustrative purposes and are not to be construed as
limiting.
[0083] It is also to be understood that variations and
modifications can be made on the aforementioned structures and
methods without departing from the concepts of the present
invention, and further it is to be understood that such concepts
are intended to be covered by the following claims unless these
claims by their language expressly state otherwise.
* * * * *