Refrigerator and ice maker apparatus

An ice maker assembly includes, in an exemplary embodiment, an ice bucket that has a bottom wall, opposing side walls extending from the bottom wall, a front wall, and a back wall. The bottom wall, side walls, front wall, and back wall define an ice collection cavity. The ice bucket also includes a plurality of ribs extending from the bottom wall into the ice collection cavity, and a rotatable auger extending between the front and back walls.

BACKGROUND OF THE INVENTION

This invention relates generally to refrigerators, and more specifically, to an ice making system for a refrigerator.

Some known refrigerators include a fresh food compartment and a freezer compartment. Such refrigerators also typically include a refrigeration circuit including a compressor, evaporator, and condenser connected in series. An evaporator fan is provided to blow air over the evaporator, and a condenser fan is provided to blow air over the condenser. In operation, when an upper temperature limit is reached in the freezer compartment, the compressor, evaporator fan, and condenser fan are energized. Once the temperature in the freezer compartment reaches a lower temperature limit, the compressor, evaporator fan, and condenser fan are de-energized.

Some refrigerator freezers include an ice maker. The ice maker receives water for ice production from a water valve typically mounted to an exterior of a refrigerator case. A primary mode of heat transfer for making ice is convection. Specifically, by blowing cold air over an ice maker mold body, heat is removed from water in the mold body. As a result, ice is formed in the mold. Typically, the cold air blown over the ice maker mold body is first blown over the evaporator and then over the mold body by the evaporator fan. The ice is typically stored in an ice bucket positioned adjacent the mold. Known ice buckets do not permit easy access to bulk ice removal, due to interference with the inner door when the refrigerator is adjacent to a wall, especially for “built-in: style refrigerators.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, an ice maker assembly for a refrigerator is provided. The ice maker assembly includes an ice bucket that includes a bottom wall, opposing side walls extending from the bottom wall, a front wall, and a back wall. The bottom wall, side walls, front wall, and back wall define an ice collection cavity. The ice bucket also includes a plurality of ribs extending from the bottom wall into the ice collection cavity, and a rotatable auger extending between the front and back walls.

In another aspect, an ice maker assembly for a refrigerator is provided. The ice maker assembly includes an ice bucket including a bottom wall, opposing side walls extending from the bottom wall, a front wall, and a back wall. The bottom wall, side walls, front wall, and back wall define an ice collection cavity. The ice bucket also includes a rotatable auger extending between the front and back walls, and an auger drive cup. The auger drive cup includes a circular ring portion having an inner surface and an outer surface. The drive cup is positioned in an opening in the back wall with the outer surface rotatably coupled to the back wall. The auger drive cup is operatively coupled to the auger. A drive post extends radially from the inner surface of the circular ring portion. The drive post includes a tapered surface facing away from the auger.

In another aspect, a refrigerator is provided. The refrigerator includes a fresh food compartment, a freezer compartment having a back wall and separated from the fresh food compartment by a mullion, a first glide track and an opposing second glide track mounted in the freezer compartment, and an ice maker positioned within the freezer compartment. The ice maker including an ice bucket slidably mounted in the freezer cavity. The ice bucket is tiltable to a downward slope from the back wall to permit access to an ice collection cavity of the ice bucket. The ice bucket includes front slide nubins and rear slide nubins extending from a first side and an opposing second side of the ice bucket. The front and rear slide nubins are sized to slide in the glide tracks. Each glide track include a track stop that acts as pivot points for tilting the ice bucket, and a tilt stop portion that engages the rear nubin to limit the amount of tilt and hold the ice bucket in place when tilted downward.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1illustrates an exemplary refrigeration appliance100in which the present invention may be practiced. In the embodiment described and illustrated herein, appliance100is a side-by-side refrigerator. It is recognized, however, that the benefits of the present invention are equally applicable to other types of refrigerators, freezers, and refrigeration appliances. Consequently, the description set forth herein is for illustrative purposes only and is not intended to limit the invention in any aspect.

Refrigerator100includes a fresh food storage compartment102and a freezer storage compartment104contained within an outer case106and inner liners108and110. A space between case106and liners108and110, and between liners108and110, is filled with foamed-in-place insulation. Outer case106normally is formed by folding a sheet of a suitable material, such as pre-painted steel, into an inverted U-shape to form top and side walls of case. A bottom wall of case106normally is formed separately and attached to the case side walls and to a bottom frame that provides support for refrigerator100. Inner liners108and110are molded from a suitable plastic material to form freezer compartment104and fresh food compartment102, respectively. Alternatively, liners108,110may be formed by bending and welding a sheet of a suitable metal, such as steel. The illustrative embodiment includes two separate liners108,110as it is a relatively large capacity unit and separate liners add strength and are easier to maintain within manufacturing tolerances. In smaller refrigerators, a single liner is formed and a mullion spans between opposite sides of the liner to divide it into a freezer compartment and a fresh food compartment.

A breaker strip112extends between a case front flange and outer front edges of liners. Breaker strip112is formed from a suitable resilient material, such as an extruded acrylonitrile-butadiene-styrene based material (commonly referred to as ABS).

The insulation in the space between liners108,110is covered by another strip of suitable resilient material, which also commonly is referred to as a mullion114. Mullion114also preferably is formed of an extruded ABS material. Breaker strip112and mullion114form a front face, and extend completely around inner peripheral edges of case106and vertically between liners108,110. Mullion114, insulation between compartments, and a spaced wall of liners separating compartments, sometimes are collectively referred to herein as a center mullion wall116.

Shelves118and slide-out drawers120normally are provided in fresh food compartment102to support items being stored therein. A bottom drawer or pan122may partly form a quick chill and thaw system (not shown) and selectively controlled, together with other refrigerator features, by a microprocessor (not shown) according to user preference via manipulation of a control interface124mounted in an upper region of fresh food storage compartment102and coupled to the microprocessor. A shelf126and wire baskets128are also provided in freezer compartment104.

Freezer compartment104includes an automatic ice maker130. An ice dispenser131is provided in freezer door132so that ice can be obtained without opening freezer door132. As will become evident below, ice maker130, in accordance with conventional ice makers includes a number of electromechanical elements that manipulate a mold to shape ice as it freezes, a mechanism to remove or release frozen ice from the mold, and a primary ice bucket for storage of ice produced in the mold. Periodically, the ice supply is replenished by ice maker130as ice is removed from the primary ice bucket. The storage capacity of the primary ice bucket is generally sufficient for normal use of refrigerator100.

Freezer door132and a fresh food door134close access openings to fresh food and freezer compartments102,104, respectively. Each door132,134is mounted by a top hinge136and a bottom hinge (not shown) to rotate about its outer vertical edge between an open position, as shown inFIG. 1, and a closed position (not shown) closing the associated storage compartment. Freezer door132includes a plurality of storage shelves138and a sealing gasket140, and fresh food door134also includes a plurality of storage shelves142and a sealing gasket144.

In accordance with known refrigerators, refrigerator100also includes a machinery compartment (not shown) that at least partially contains components for executing a known vapor compression cycle for cooling air. The components include a compressor (not shown), a condenser (not shown), an expansion device (not shown), and an evaporator (not shown) connected in series and charged with a refrigerant. The evaporator is a type of heat exchanger which transfers heat from air passing over the evaporator to a refrigerant flowing through the evaporator, thereby causing the refrigerant to vaporize. The cooled air is used to refrigerate one or more refrigerator or freezer compartments via fans (not shown). Collectively, the vapor compression cycle components in a refrigeration circuit, associated fans, and associated compartments are referred to herein as a sealed system. The construction of the sealed system is well known and therefore not described in detail herein, and the sealed system is operable to force cold air through the refrigerator.

FIG. 2is a cross sectional view of an icemaker130including a metal mold150with a tray structure having a bottom wall152, a front wall154, and a back wall156. A plurality of partition walls158extend transversely across mold150to define cavities in which ice pieces160are formed. Each partition wall158includes a recessed upper edge portion162through which water flows successively through each cavity to fill mold150with water.

A sheathed electrical resistance heating element164is press-fit, staked, and/or clamped into bottom wall152of mold150and heats mold150when a harvest cycle is executed to slightly melt ice pieces160and release them from the mold cavities. A rotating rake166sweeps through mold150as ice is harvested and ejects ice from mold150into a storage bin168or ice bucket. Cyclical operation of heater164and rake166are effected by a controller170disposed on a forward end of mold150, and controller170also automatically provides for refilling mold150with water for ice formation after ice is harvested through actuation of a water valve (not shown inFIG. 2) connected to a water source (not shown) and delivering water to mold150through an inlet structure (not shown).

In order to sense a level of ice pieces160in storage bin,168controller actuates a cam-driven feeler arm172rotates underneath icemaker130and out over storage bin168as ice is formed. Feeler arm172is spring biased to an outward or “home” position that is used to initiate an ice harvest cycle, and is rotated inward and underneath icemaker by a cam slide mechanism (not shown) as ice is harvested from icemaker mold150so that the feeler arm does not obstruct ice from entering storage bin168and to prevent accumulation of ice above the feeler arm. After ice is harvested, the feeler arm is rotated outward from underneath icemaker130, and when ice obstructs the feeler arm and prevents the feeler arm from reaching the home position, controller170discontinues harvesting because storage bin168is sufficiently full. As ice is removed from storage bin168, feeler arm172gradually moves to its home position, thereby indicating a need for more ice and causing controller170to initiate formation and harvesting of ice pieces160.

FIG. 3is a top perspective view of ice bucket168,FIG. 4is a rear perspective view of ice bucket168, andFIG. 5is an enlarged rear view of the ice bucket168. Referring toFIGS. 3–5, ice bucket168includes a bottom wall176, opposing side walls178and180, a front wall182, and a back wall184. Bottom wall176, side walls178and180, front wall182, and back wall184define an ice collection cavity186. A plurality of ribs188extend from bottom wall182into ice collection cavity186. A rotatable auger190extends between front and back walls182and184. Each rib188extends from side wall178or180towards auger190, and each rib188is tapered from side wall178or180. Ribs188aid in guiding ice pieces160into auger190for dispensing. Ribs188also maintain ice cubes160in position within ice collection cavity186and create a “positive pressure” to assist in feeding ice cubes160into auger190. Ribs188further act to break ice pile forces to permit ice to feed into auger190, and act to break the ice into sections to permit the sections of ice to act independently.

Referring also toFIGS. 4–6, auger190is operatively coupled to an auger drive cup192so that when drive cup192is turned, auger190also turns. Particularly, an end portion191of auger190engages slot195of drive cup192to couple auger190to drive cup192. Drive cup192includes a circular ring portion194having an inner surface196and an outer surface198. Drive cup outer surface198is rotatably coupled to back wall84. Particularly, drive cup192is positioned in an opening200in bucket back wall84. A drive post202extends radially from inner surface196of ring portion194. Drive post202has a tapered surface204that faces away from auger190. Drive post202is located about 180 degrees from end portion191of auger190when end portion191is engaged in slot195of drive cup192.

A drive fork206operatively coupled to a drive motor (not shown) includes a base portion208having a first end210and a second end212. A first engagement tang214extends from first end210of base portion208. First engagement tang214includes a first tapered portion216extending from a first side edge218to a tip220and a second tapered portion222extending from a second side edge224to tip220. Tip220is off centered between side edges218and224. A second tang226extends from second end212of base portion208. First tang214has a longer length than second tang226. Second tang226includes a tapered portion228extending from a first side edge230to a second side edge232. An intersection of tapered portion228and second side edge232defines a tip234of second tang226.

FIG. 4shows drive fork206before engagement with drive cup192whileFIG. 5shows drive fork206engaged with drive cup192. Because of its longer length, first tang214engages drive cup192first as bucket168is moved into position inside freezer compartment104. Off centered tip220forces drive cup192to turn counter clockwise as first tang214engages auger190which is attached to drive cup192. As ice bucket168is pushed into place, drive cup192turns until second tang226engages drive post202. Tapered or inclined surface204of drive post202aids in rotating drive cup192counter clockwise as ice bucket168reaches its final position inside freezer compartment104. Also tapered surface204of drive post202ensures that second tang226engages drive cup192on opposite side of first tang214.

Referring again toFIGS. 1,3,4,8and9ice bucket168includes front slide nubins236and238extending from side walls178and180respectively, and rear slide nubins240and242extending from side walls178and180respectively. Front and rear slides236,238,240, and242ride or slide in glide tracks244and246attached to side walls248and250of freezer compartment104As seen inFIG. 4, rear slide nubins240and242are configured so that ice bucket168slopes upward from a back wall252of freezer compartment104when in a stored position.FIG. 8shows ice bucket168in this upward sloped position. This upward sloped position of ice bucket168inside freezer compartment104permits ice maker130to be mounted at the top of freezer compartment104and provide for a maximum amount of usable storage space inside freezer compartment104. However, in alternate embodiments, ice bucket168is mounted in a horizontal position. To permit manual access to ice stored in ice bucket168, ice bucket168can be slid forward with slides236,238,240, and242sliding in glide tracks244and246until rear slides240and242contact stops254and256in glide tracks244and246. The front of ice bucket168then tilts downward using stops254and256as pivot points thereby pivoting ice bucket168downward until rear slides240and242contact tilt stop portions258and260of glide tracks244and246.

Front slide nubins236and238include a substantially V-shaped engagement portion262that is sized to engage a detent264in glide tracks244and246. Engagement portion262includes a front edge portion266, a front ramp portion268, and a rear ramp portion270. Front and rear ramp portions268and270join at an apex272of engagement portion262.

To actuate the tilt feature of bucket168, a user moves ice bucket168forward, lifting front nubins236and238off glide tracks244and246to disengage from detents264, until rear nubins240and242engage stops254and256. The center of gravity of ice bucket168permits tilt using glide track stops254and256as the pivot points and rotates until rear nubins240and242engage tilt stop portions258and260of glide tracks244and246. The above described tilt feature is operational when the freezer door is opened only 90 degrees.

Known ice buckets sometimes become unseated during use or auger operation, and drive freezer door open. Also, known ice buckets sometimes do not reliably seat properly, holding the freezer door partially open. The above described front nubin engagement portion262and track detent264maintains positive seating of ice bucket168during operation. The vertical travel from apex272to the nubin base prevents unseating of ice bucket168during operation. Also, engagement portion162ensures that travel by closing the door will positively seat ice bucket168into detent264if ice bucket168has not been seated properly before closing the door. Front ramp portion268assisted by gravity, carries engagement portion262into detent264. Front edge portion264provides the positive stop for ice bucket168so that even if bucket168jumps during operation, engagement portion262will self-seat into detent264.