Abstract:
An ice dispenser for a refrigeration appliance is provided that can deliver both crushed ice and whole or non-crushed ice. A rotating drum or cylinder carries one or more blades that can crush ice against non-rotating blades carried on an axis or rod that extends into the drum. The direction of rotation of the drum can be selected so as to determine whether crushed or non-crushed ice is dispensed. The dispensing system can be located on the door of the refrigerator. An ice maker can also be positioned with the ice dispenser on the door of the appliance or, optionally, can be located in a compartment of the refrigerator.

Description:
PRIORITY CLAIM 
       [0001]    This application is a continuation-in-part application of and claims priority to U.S. patent application Ser. No. 13/285,122 filed on Oct. 31, 2011, which is incorporated herein by reference for all purposes. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The subject matter of the present disclosure relates to an ice dispenser for a refrigerator appliance and, more specifically, to an ice dispenser also having an ice crusher. 
       BACKGROUND OF THE INVENTION 
       [0003]    Generally, a refrigerator includes a freezer compartment and a fresh food compartment, which are partitioned from each other to store various foods at appropriate low temperatures. It is common to provide an automatic icemaker/water dispenser with a refrigerator. In a “side-by-side” type of refrigerator where the freezer compartment is arranged to the side of the fresh food compartment, the icemaker is usually disposed in the freezer compartment and, thus, utilizes the cold air in the freezer compartment, which typically includes an evaporator also disposed in the freezer compartment. 
         [0004]    In a “bottom freezer” type of refrigerator where the freezer compartment is arranged beneath a top mounted fresh food compartment, convenience necessitates that the icemaker is disposed in a sub-compartment (often referred to as an “icebox”) that is usually thermally insulated and configured in one of the top mounted fresh food compartment doors with ice delivered through an opening on the door. In such an arrangement, provision must be made for providing adequate refrigeration to the icebox to enable the icemaker to form and store the ice. An access door is commonly provided on the icebox to allow the consumer to access the internal ice bucket and icemaker. 
         [0005]    Typically, the ice maker delivers ice into a storage container or bucket where the ice is kept until used. A panel on the front of the refrigerator allows the user to select between the dispensing of crushed ice or non-crushed ice. Conventionally, the ice is pushed by e.g., an auger through a chute or channel equipped with one or more blades, which are carried on a shaft and rotate with the shaft to contact and crush the ice. Chilled water can also be provided by routing a thermally conductive conduit to the panel such that the water is cooled before reaching the dispenser. 
         [0006]    The ice container and dispenser can consume a significant amount of space from the freezer or fresh food compartment. Space is consumed not only by the volume required for ice creation and storage, but the mechanisms for moving and/or crushing the ice can also consume space the user might otherwise prefer to have available for food storage. Additionally, the mechanisms needed for crushing ice can also consume additional space. Depending upon how the components are positioned within these compartments, user access to portions of the compartment and/or to the ice storage container (e.g., for cleaning or manually collecting ice) can be inconvenient as well. 
         [0007]    Accordingly, an ice dispensing system for a refrigerator appliance would be useful. More particularly, an ice dispensing system for a refrigerator appliance that can allow for the positioning of the ice storage container and/or ice crushing mechanism on a door of the refrigerator would be beneficial as it could provide savings in space. Additionally, such a system that can provide more convenient access to the refrigerator compartments and/or the ice storage container would be also be useful. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0008]    The present invention provides an ice dispensing system for a refrigeration appliance. The ice dispensing system includes a mechanism for crushing ice such that both crushed ice or non-crushed ice can be dispensed to a user of the appliance. A rotating drum or cylinder carries one or more blades that can crush ice against non-rotating blades carried on an axis or rod that extends into the drum. The direction of rotation of the drum can be selected so as to determine whether crushed or non-crushed ice is dispensed. The dispensing system can be located on the door of the refrigerator. An ice maker can also be positioned with the ice dispenser on the door of the appliance or, optionally, can be located in a compartment of the refrigerator. Additional aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention. 
         [0009]    In one exemplary embodiment, the present invention provides an ice dispensing assembly for an appliance. The assembly includes a container for the receipt of ice. The container has a bottom defining a first opening for the passage of ice from the container. A cylindrically-shaped sleeve is connected with the opening at the bottom of the container and extending from the bottom of the container. A base is connected with the sleeve and defines a second opening for the passage of ice from the container. A cylinder is positioned at least partially within the sleeve and is rotatable with respect to the sleeve. The cylinder has a wall and defines an inner diameter. At least one rotatable blade extends along the inner diameter between opposing ends positioned at the wall of the cylinder. The at least one rotatable blade defines a guide hole that is centrally positioned along the at least one rotatable blade. A shaft extends into the cylinder and through the guide hole of the at least one rotatable blade. The shaft has a bottom end connected to the base. At least one non-rotating blade is attached to the shaft. 
         [0010]    In another exemplary embodiment, the present invention provides a refrigerator that includes a cabinet, a fresh food compartment, a freezer compartment, or both, and an ice maker. An ice dispensing assembly is provided that comprises a container for the receipt of ice from the ice maker. The container has a bottom defining a first opening for the passage of ice from the container. A cylindrically-shaped sleeve is connected with the opening at the bottom of the container and extends from the bottom of the container. A base is connected with the sleeve. The base defines a second opening for the passage of ice from the container. A cylinder is positioned at least partially within the sleeve and is rotatable with respect to the sleeve. The cylinder has a wall and defining an inner diameter. At least one rotatable blade extends along the inner diameter between opposing ends positioned at the wall of the cylinder. The at least one rotatable blade defines a guide hole that is centrally positioned along the at least one rotatable blade. A shaft extends into the cylinder and through the guide hole of the at least one rotatable blade. The shaft has a bottom end connected to the base. At least one non-rotating blade is attached to the shaft. 
         [0011]    These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which: 
           [0013]      FIG. 1  illustrates an exemplary embodiment of a refrigerator appliance as may be used with the present invention. 
           [0014]      FIG. 2  provides another illustration of the exemplary embodiment of  FIG. 1  with doors to the fresh food compartment shown in an open position. 
           [0015]      FIG. 3  depicts a perspective view of an ice storage container and crusher in an exemplary embodiment of an ice dispensing assembly of the present invention. For purposes of revealing interior components in this view, a portion of the storage container is removed. 
           [0016]      FIG. 4  illustrates a cross-sectional view of a bottom portion of the exemplary ice storage container of  FIG. 3 . 
           [0017]      FIG. 5  is perspective view of the bottom of the exemplary ice storage container of  FIG. 3 . 
           [0018]      FIG. 6  provides a side view of an exemplary cylinder as used with the ice storage container of  FIG. 3 . 
           [0019]      FIG. 7  is a top perspective view of the exemplary cylinder of  FIG. 6 . 
           [0020]      FIG. 8  is a top perspective view of the exemplary cylinder of  FIG. 6  with a metering plate removed to more fully illustrate other components. 
           [0021]      FIG. 9  is a partial cross-sectional view of the exemplary embodiment of the ice storage container shown in  FIG. 4  along with an exemplary motor connected with the cylinder. 
           [0022]      FIG. 10  is a partial cross-sectional view of a portion of the exemplary ice storage container shown in  FIG. 3 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0023]    Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
         [0024]      FIG. 1  is a front view of a refrigerator  100  including an ice-dispensing assembly  110  for dispensing water and/or ice. In this exemplary embodiment, ice-dispensing assembly  110  includes a dispenser  114  positioned on an exterior portion of refrigerator  100 . Refrigerator  100  includes a cabinet  120  having an upper fresh food compartment  122  and a lower freezer compartment  124  arranged at the bottom of refrigerator  100 . As such, refrigerator  100  is generally referred to as a bottom mount refrigerator. In the exemplary embodiment, cabinet  120  also defines a mechanical compartment (not shown) for receipt of a sealed cooling system. Using the teachings disclosed herein, one of skill in the art will understand that the present invention can be used with other types of refrigerators (e.g., side-by-sides) as well. Consequently, the description set forth herein is for illustrative purposes only and is not intended to limit the invention in any aspect. 
         [0025]    Refrigerator doors  126 ,  128  are rotatably hinged to an edge of cabinet  120  for accessing fresh food compartment  122 . A freezer door  130  is arranged below refrigerator doors  126 ,  128  for accessing freezer compartment  124 . In the exemplary embodiment, freezer door  130  is coupled to a freezer drawer (not shown) slidably coupled within freezer compartment  124 . 
         [0026]    For this exemplary embodiment, dispenser  114  includes a discharging outlet  132  for accessing ice and water. A single paddle  134  is mounted below discharging outlet  132  for operating dispenser  114 . A user interface panel  136  is provided for controlling the mode of operation. For example, user interface panel  136  includes a water dispensing button (not labeled) and an ice-dispensing button (not labeled) for selecting a desired mode of operation such as crushed or non-crushed ice. 
         [0027]    Discharging outlet  132  and paddle  134  are an external part of dispenser  114 , and are mounted in a concave portion  138  defined in an outside surface of refrigerator door  126 . Concave portion  138  is positioned at a predetermined elevation convenient for a user to access ice or water enabling the user to access ice without the need to bend-over and without the need to access freezer compartment  124 . In the exemplary embodiment, concave portion  138  is positioned at a level that approximates the chest level of a user. 
         [0028]      FIG. 2  is a perspective view of refrigerator  100  having doors  126 ,  128  in an open position to reveal the interior of the fresh food compartment  122 . As such, certain components of this exemplary embodiment of the ice dispensing assembly  110  are illustrated. Ice-dispensing assembly  110  includes an insulated housing  142  mounted within refrigerator compartment  122  along an upper surface  144  of compartment  122  and along a sidewall  146  of compartment  122 . Insulated housing  142  includes insulated walls  148  defining an insulated cavity (not shown). Due to the insulation which encloses the cavity, the temperature within the cavity can be maintained at levels different from the temperature in the surrounding fresh food compartment  122 . 
         [0029]    In this exemplary embodiment, the insulated cavity is constructed and arranged to operate at a temperature that facilitates producing and storing ice. More particularly, the insulated cavity contains an ice maker for creating ice and feeding the same to a container  200  that is mounted on refrigerator door  126 . As illustrated in  FIG. 2 , container  200  is placed at a vertical position on refrigerator door  126  that will allow for the receipt of ice from a discharge opening  162  located along a bottom edge  164  of insulated housing  142 . As door  126  is closed or opened, container  200  is moved in and out of position under insulated housing  142 . Alternatively, in another exemplary embodiment of the present invention, insulated housing  142  and its ice maker can be positioned directly on door  126 . In still another embodiment of the present invention, in a configuration where the fresh food compartment and the freezer compartment are located side by side (as opposed to over and under as shown in  FIGS. 1 and 2 ), the ice maker could be located on the door for the freezer compartment and directly over container  200 . As such, the use of an insulated housing would be unnecessary. Other configurations for the location of ice container  200 , an ice maker, and/or insulated housing  142  may be used as well. 
         [0030]    Operation of the refrigerator  100  can be regulated by a controller (not shown) that is operatively coupled to user interface panel  136  and/or paddle  134 . Panel  136  provides selections for user manipulation of the operation of refrigerator  100  such as e.g., selections between whole or crushed ice, chilled water, and/or other options as well. In response to user manipulation of the user interface panel  136 , the controller operates various components of the refrigerator  100 . The controller may include a memory and one or more microprocessors, CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of refrigerator  100 . The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. 
         [0031]    The controller may be positioned in a variety of locations throughout refrigerator  100 . In the illustrated embodiment, the controller may be located within the control panel area of door  126 . In such an embodiment, input/output (“I/O”) signals may be routed between the controller and various operational components of refrigerator  100  such as a motor for rotating components of an ice crusher as will be described further below. In one embodiment, the user interface panel  136  may represent a general purpose I/O (“GPIO”) device or functional block. In one embodiment, the user interface  136  may include input components, such as one or more of a variety of electrical, mechanical or electro-mechanical input devices including rotary dials, push buttons, and touch pads. The user interface  136  may include a display component, such as a digital or analog display device designed to provide operational feedback to a user. The user interface  136  may be in communication with the controller via one or more signal lines or shared communication busses. 
         [0032]    An exemplary embodiment of the ice storage container  200  along with an ice crushing mechanism as may be used with ice dispensing assembly  110  is further illustrated in  FIG. 3 . For purposes of revealing interior components in this view, a portion of the storage container  200  is removed. Container  200  has a bottom  202  that defines a first opening  204 .  FIG. 4  illustrates a cross-sectional view taken at the bottom  202  of container  200  near first opening  204 . Ice (not shown) can pass from container  200  and through opening  204  into a drum or rotatable cylinder  208 . Bottom  202  is sloped towards first opening  204  to help direct ice towards first opening  204  as indicated by arrow S. 
         [0033]    As shown, cylinder  208  is positioned at first opening  204  within a cylindrically-shaped sleeve  206  that is also located at first opening  204 . Sleeve  206  is connected with the bottom  202  of container  200  and is integrally formed with container  200 . As shown in the perspective view of the bottom of container  200  provided in  FIG. 5 , a base  214  is connected with sleeve  206 . Base  214  closes off sleeve  206  except for a second opening  216  through which ice may flow for dispensing. Cylinder  208  is rotatable with respect to sleeve  206 . The movement of cylinder  208  is created by a motor  234  ( FIG. 3 ) as will be further described. 
         [0034]    Referring now to  FIGS. 4 through 9 , a plurality of rotatable blades  218  are carried by cylinder  208  as it rotates within sleeve  206 . Blades  218  extend along the inner diameter  212  of cylinder  208  between opposing ends  220  ( FIG. 9 ) that in turn are positioned at the wall  210  of cylinder  208 . Although two rotatable blades  218  are shown, one or more such blades may be used in other embodiments of the present invention. Rotatable blades  218  include teeth  270  for crushing ice. 
         [0035]    A bridge  248  extends between opposing ends  250  that are connected to the wall  210  of cylinder  208 . Bridge  248  projects from cylinder  208  along vertical direction V. Accordingly, cylinder  208  and bridge  246  rotate together. The movement of bridge  248  stirs ice in container  200  to help move the ice into opening  204 . The shape or appearance of bridge  246  can have other configurations different from that shown in the figures. 
         [0036]    A non-rotating shaft  224  extends into cylinder  208  along vertical direction V. Shaft  224  has a bottom end  226  that is fixed into base  214 . More particularly, as best seen in  FIG. 5 , bottom end  226  has a hexagonal shape received in a complementary manner into a hexagonally-shaped hole  266  in base  214 . A plurality of struts  264  extend between the sides of container  200  and provide structural support. For this exemplary embodiment, container  200  is constructed from a plastic material along with struts  264 . One or more of these struts  264  can incorporate reinforcement such as e.g., a steel bar positioned within strut  264  using an insert molding process. 
         [0037]    Shaft  224  also extends through guide holes  222  in rotatable blades  218 , which can freely rotate with cylinder  208  since shaft  224  and rotatable blades  218  are not connected. The top end  258  of shaft  224  is received into a guide hole  256  in the central portion  254  of bridge  248 . The diameter of guide hole  256  is slightly larger than the diameter of the top end  258  of shaft  224 . As such, bridge  248  can freely rotate with cylinder  208  about fixed shaft  224  to stir the ice. At the same time, bridge  248  helps support shaft  224  and orient top end  258 . 
         [0038]    As best shown in  FIGS. 7 and 8 , bridge  248  and rotatable blades  218  can be constructed as an integral piece from e.g., a metal such as steel. During assembly, this integral piece can be slid into cylinder  208  along with a pair of opposing recesses  252  in wall  210 . Other configurations may be used as well for construction of blades  218 , bridge  248 , and cylinder  208 . 
         [0039]    Referring to  FIGS. 7 and 10 , a plurality of non-rotatable blades  268  are attached to shaft  224  and do not rotate with cylinder  208 . For this exemplary embodiment of ice container  200 , blades  268  extend from shaft  224  along one side to wall  210  but without connecting to wall  210 . During operation, rotation of cylinder  208  in the direction of arrow C moves the teeth  270  of rotatable blades  218  towards the teeth  272  of non-rotating blades  268 . Accordingly, ice delivered into cylinder  208  from container  200  will be crushed between teeth  270  and  272  to provide crushed ice to the user. Conversely, by rotating cylinder  208  in the direction of arrow NC, the teeth  270  of rotatable blades  218  will be moved away from teeth  272  of non-rotating blades  268 . As such, ice delivered into cylinder  208  from container  200  will not be crushed so that whole ice can be delivered to the user. 
         [0040]    The amount of ice delivered into cylinder  208  from container  200  is controlled by a metering plate  240 . As best shown in  FIGS. 4 and 7 , metering plate  240  is attached to fixed shaft  224  and does not rotate with cylinder  208 . Metering plate  240  defines an opening or aperture  242  through which ice must pass in order to move through cylinder  208 . As such, aperture  242  can be sized to provide the desired flow rate of ice from container  200 . Teeth  244  positioned along an edge of metering plate  240  help crush ice as cylinder  200  rotates so as to prevent jams. 
         [0041]    As previously indicated, motor  234  is used to rotate cylinder along either direction C or direction NC. As shown in  FIGS. 4 through 9 , the bottom end  230  of cylinder  200  is provided with a first plurality of gear teeth  232  positioned circumferentially around cylinder  200 . Teeth  232  extend through a slot  274  in base  214  ( FIG. 5 ). As best shown in  FIG. 6 , the first plurality of gear teeth  232  each have a beveled surface  238 . 
         [0042]    Referring to  FIG. 3 , teeth  232  of cylinder  200  are driven by a second plurality of gear teeth  236  of motor  234 . Teeth  236  are also beveled in a complementary manner to gear teeth  232 . Motor  234  is affixed to a base or platform  198  on door  126 . During operation, a user may remove ice container  200  from platform  198  on door  126  in order to clean container  200  and/or dump ice. This removal disengages gear teeth  270  and  272  from each other. Upon returning container  200  to platform  198 , it is important for gear teeth  270  and  272  to reengage or mesh so that motor  234  can rotate cylinder  208 . Accordingly, the beveling of teeth  232  and  236  provide for proper realignment so that teeth will properly reengage when container  200  is placed back onto platform  198 . 
         [0043]    Additionally, container  200  also includes a skirt  260  with flange  262  that each extend around container  200  as shown in  FIG. 3 . Skirt  260  includes a slight taper along the vertical direction. For example, the taper may be about 5 to 7 degrees from the vertical direction. This taper helps container  200  properly seat and re-align when positioned onto platform  198 . 
         [0044]    During rotation of cylinder  208  as described, considerable torque may be provided by motor  234 . In order to maintain the alignment of cylinder  208 , base  214  is provided with a circumferentially-extending groove  246 . The bottom end  230  of cylinder  208  is received into groove  246  as shown in  FIG. 4 . Circumferentially-extending groove  276  at top end  228  of cylinder  208  performs a similar function. 
         [0045]    By way of example of the operation of ice dispensing assembly  110 , ice is dropped into container  200  from the ice maker through opening  162  in insulated housing  142 . The slope of bottom  202  directs ice toward first opening  204  (arrow S in  FIG. 3 ) so that ice may move through aperture  242  in metering plate  240  and into cylinder  208  under the force of gravity. The rotation of cylinder  208  helps stir the ice and facilitate movement as bridge  248  will move ice near bottom  202 . 
         [0046]    Depending upon whether the user has selected crushed or whole ice using interface panel  136 , the controller can determine the direction of rotation of cylinder  208  by powering motor  234  as required. Such rotation could be activated based upon e.g., the depressing of paddle  134  by a user such that a request for ice is received by the controller. The controller could then activate motor  234  in the proper direction for crushed or whole ice. 
         [0047]    If the user has selected crushed ice, cylinder  208  is rotated so that the movement of rotatable blades  218  relative to the non-rotating blades  268  will pinch and then crush ice between teeth  270  and  272  (arrow C in  FIG. 7 ). As ice travels vertically down through cylinder  208 , multiple blades  218  and  268  can be provided as shown so as to help ensure that the ice is crushed sufficiently. Alternatively, if the user has selected whole or non-crushed ice, drum  206  is rotated so that the movement of rotatable blades  210  relative to non-rotating blades  268  will avoid crushing ice therebetween (arrow NC in  FIG. 7 ). After travelling down sleeve  206 , crushed or whole ice can exit through second opening  216  and pass through discharge outlet  132  into e.g., the user&#39;s cup or glass. 
         [0048]    This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.