Patent Publication Number: US-8109114-B2

Title: Ice maker and control method of same

Description:
BACKGROUND 
     This application claims the benefit of Korean Patent Application No. 10-2007-0071153, filed in Korea on Jul. 16, 2007, which is hereby incorporated by reference in its entirety as if fully set forth herein. 
     1. Field 
     This relates to an ice maker and a controlling method thereof, and more particularly, to an ice maker that is capable of preventing the overflow or splashing of water or thin ice out of an ice tray as water is supplied to the ice tray, or when the ice tray is shaken by an external force, and a controlling method of such an ice maker. 
     2. Background 
     Generally, an ice maker is provided in a freezing apparatus such as, for example, a refrigerator, a water purifier, a vending machine, and an ice making apparatus (hereinafter, referred to as “a refrigerator or the like”). In a simple ice making systems, a container containing water is placed in a freezing chamber and the water is frozen below the freezing point to produce ice. The container may be an ice tray having an interior divided into a plurality of spaces into which water may be supplied and frozen into ice. The ice may then be separated from the container manually, or in an automated manner. In a manual system, a user manually removes the ice from the freezing chamber. 
     Ice trays may be classified as a heating type ice tray or as a twist type ice tray based on how the ice is separated from the tray. In an automated heating type ice tray, a heater heats the ice tray such that the outer surface of the ice in the ice tray melts and separates from the ice tray. In a twist type ice tray, the ice tray is twisted, and the ice is separated from the ice tray without the use of a heater. An ice separating system and method which minimizes or eliminates the flow of water and/or partially frozen, thin pieces of ice, out of the tray is desirable. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The embodiments will be described in detail with reference to the following drawings in which like reference numerals refer to like elements wherein: 
         FIG. 1  is a perspective view of an ice maker according to an embodiment as broadly described herein; 
         FIG. 2  is a perspective view of an ice tray of the ice maker shown in  FIG. 1 ; 
         FIG. 3  is a perspective view of an ice maker according to an embodiment as broadly described herein; 
         FIG. 4  is a perspective view of an ice tray and ice tray cover as embodied and broadly described herein; 
         FIG. 5  is a side view of an ice maker according to an embodiment as broadly described herein; 
         FIG. 6  is a side view of an ice maker according to an embodiment as broadly described herein; 
         FIG. 7  is a top perspective view of the ice tray cover shown in  FIG. 6 ; 
         FIGS. 8A-8E  illustrate a sequence in an operation process of the ice maker shown in  FIG. 3 ; 
         FIGS. 9A-9D  illustrate a sequence in an operation process of the ice maker shown in  FIG. 5 ; 
         FIGS. 10A-10E  illustrate a sequence in an operation process of the ice maker shown in  FIG. 6 ; and 
         FIG. 11  is a flow chart of a controlling method of an ice maker according to an embodiment as broadly described herein. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. 
     An ice separating system may include an ice tray made of a conductive material. A pulse may be applied to the ice tray for a short period of time to melt outer surfaces of the ice that are in contact with the ice tray to release a bond therebetween so that the ice may be separated form the ice tray. The relatively short heating period may minimize excess water generation during melting and may maintain the ice in a desired shape. 
     However, water or thin ice may splash out of or overflow from the ice tray during the supply of water into the ice tray or during the production of ice. More specifically, water may splash as it is supplied to the ice tray, or the ice maker in which the ice tray is mounted, may be shaken by an external force during the production of ice, and water or thin ice may overflow from the ice tray. 
     Consequently, the water may be introduced into an ice storage box and then re-frozen into ice. This causes ice pieces stored in the storage box to stick to each other, causing difficulty in removal and use. Also, water may infiltrate and be frozen in/on peripheral components adjacent to the ice maker, thus degrading the freezing efficiency of the ice maker and the overall reliability of the system. 
     As shown in  FIGS. 1-3 , an ice maker  100  according to embodiments as broadly described herein may include an ice tray  110  that receives water to be frozen into ice, and an ice tray cover  150  positioned above the ice tray  110  to prevent the overflow or splashing of water from the ice tray  110 . Such an ice tray cover  150  may be used with a heating type ice tray or a twist type ice tray. 
     The ice tray  110  may include at least one receiving part  112  that receives water to produce ice. The top of the at least one receiving part  112  may include an opening through which water may be supplied to the ice tray, and through which the ice may be discharged from the ice tray. 
     As shown in  FIGS. 1 and 2 , ice tray  110  may include a plurality of receiving parts  112  arranged, for example, in a line. Alternatively, the ice tray  110  may include a plurality of receiving part lines, each of which includes a plurality of receiving parts  112  arranged in a line, the receiving part lines being arranged parallel to each other. The receiving parts  112  may be formed in various different shapes. For example, the receiving parts  112  may be formed in the shape of a hemisphere or a cube. The ice tray  110  may include receiving parts  112  formed in other shapes, including more complicated shapes, such as, for example, a star, a heart, or other shapes desired by a user. 
     The ice maker  100  may include a moving part that moves the ice tray  110  between an initial position and an ice separation position such that, after the water contained in the ice tray  110  is frozen into ice, the produced ice may be separated and discharged from the ice tray  110 . The moving unit may linearly or rotatably move the ice tray  110 . When the moving unit is constructed to rotate the ice tray  110 , the moving unit may rotate the ice tray  110  about a central axis of the ice tray  110  that extends in a longitudinal direction of the ice tray  110  (in the direction in which the receiving parts  112  are arranged in a line) such that the open top of each receiving part  112  is directed upward when the ice tray  110  is in the initial position, and downward when the ice tray  110  is in the separation position. 
     The moving unit may include a rotary member  122  that is axially coupled to opposite ends of the ice tray  110 , and a motor (not shown) provided at one side of the rotary member  112  for rotating the ice tray  110  as well as the rotary member  122 . When ice production is completed, the motor may be driven to rotate the ice tray  110 , which is coupled to the rotary member  122 . Alternatively, the rotary member  122  may be fixed such that the motor rotates only the ice tray  110 . 
     The ice tray  110  may have a rotation angle of 90 to 180 degrees. When the rotation angle of the ice tray  110  is within this range, the ice, after being separated from the ice tray  110 , may fall into an ice storage bin (not shown) by virtue of its own weight, without further movement of the ice by an additional apparatus. 
     The ice maker  100  may also include a water supply unit that supplies water to the ice tray  110 . The water supply unit may include a storage container  132  that receives and stores water, and a water supply pipe  134  that supplies water from the storage container  132  to the ice tray  110 . In certain embodiments, the storage container  132  may be connected to a water supply hose  136  such that water may be supplied to the storage container  132  from an external source. An opening and closing unit (not shown) may be provided at the connection between the water supply pipe  134  and the storage container  132  to control the flow of water therebetween such that water is supplied to the ice tray  110  only when needed. 
     The ice maker  100  may also include a heating unit that heats the ice tray  110  so as to facilitate the separation of the ice from the ice tray  110 . The heating unit partially or entirely melts the ice at an interface between the ice and the ice tray  110 , thus releasing a bond between the ice and the ice tray  110  and allowing the ice to be separated and discharged from the ice tray  110 . 
     The heating unit may include any kind of heater or heat generating member that can be intermittently turned on/off. In certain embodiments, the ice tray  110  may be made of a conductive material, and a pulse may be applied to the ice tray  110  such that the ice at the interface with the tray  110  may be melted, and the ice may be separated from the ice tray  110 . 
     For this purpose, the heating unit may include a current supplier  142  that supplies current to the ice tray  110 . The current supplier  142  may include a power supply  143  and an input controller  144 . In certain embodiments, the heating unit may be constructed to include the ice tray  110  made of the conductive material. 
     In this instance, the ice tray  110  made of the conductive material allows current to flow therethrough. Thus, the ice tray  110  may be made of a material having a high electrical conductivity, such as, for example, copper (Cu), silver (Ag), aluminum (Al), a stainless steel alloy, an aluminum alloy, or other material as appropriate. When electrodes  114  are connected to the ice tray  110 , and a pulse is applied to the ice tray  110  through the electrodes  114 , the ice tray  110  may be uniformly heated in a short period of time. 
     As shown in  FIG. 2 , electrodes  114  may be fitted in the opposite ends of the ice tray  110 , and an electric circuit (not shown) may be connected to the electrodes  114  such that current flows through the ice tray  110 . In this case, the electric circuit, which is connected to the electrodes  114 , may be provided in the rotary member  122 , or other location as appropriate. 
     When a pulse is applied to the ice tray  110  for a predetermined period of time, and the ice tray  110  is heated, the ice may be melted at the interface between the receiving parts  112  of the ice tray  110  and the ice produced in the receiving parts  112 . As a result of this melting, a bond between the ice and the receiving parts  112  may be released, and the ice may be separated and discharged from the receiving parts  112 . At this point, the ice tray  110  has already been rotated downward, and therefore, the ice falls from the ice tray  110  and into a storage bin by virtue of its own weight. 
     The amount of heat generated through the ice tray  110  may be controlled by controlling the application of current supplied from the power supply  143  in the form of a pulse by the input controller  144 . The input controller  144  may include, for example, a resistance circuit, a triac circuit, a coil circuit, or other type of circuit as appropriate. 
     As shown in  FIGS. 3 to 7 , an ice maker according to embodiments as broadly described herein may include an ice tray cover  150  positioned above the ice tray  110  to prevent the overflow or splashing of water from the ice tray  110 . The ice tray cover  150  may close off the openings of the respective receiving parts  112  of the ice tray  110  to prevent the splashing or overflow of water or thin ice from the ice tray  110  when the ice tray  110  is shaken by an external force. 
     The ice tray cover  150  may be coupled by a hinge to one side of a main body (not shown) of the ice maker  100  to allow the ice tray cover  150  to rotate and cover or expose the ice tray  110  as necessary. The ice tray cover  150  may include at least one connection member  152  that extends between one side of the ice tray cover  150  and the main body of the ice maker  100 . An end of the at least one connection member  152  may include a hinge  151  that rotatably couples the connection member  152  to the main body of the ice maker  100 . In alternative embodiments, the at least one connection member  152  may be hinged to another component of the ice maker  100  as appropriate for the particular installation. The at least one connection member  152  may rotate about the hinge  151  in the forward or reverse direction by a drive motor (not shown), with the result that the ice tray cover  150  covers or exposes the openings in the ice tray  110 . 
     Consequently, when water is supplied to the ice tray  110  or when the ice tray  110  is rotated such that ice is discharged from the ice tray  110 , the ice tray cover  150  may be rotated about the hinge by the drive motor to expose the openings in the ice tray  110  so that the water supply or the ice discharge may be carried out. During ice production, after water has been supplied, the ice tray cover  150  may be rotated downward by the drive motor to cover the top of the ice tray  110 . 
     In certain embodiments, the bottom of the ice tray cover  150  may be formed to correspond to the shape of the top of the ice tray  110 , and the bottom of the ice tray cover  150  may thus form a seal over the receiving parts  112  of the ice tray  110 , as shown in  FIG. 4 . The ice tray cover  150  may be made of a flexible material so that the ice tray cover  150  may be brought into tight contact with the ice tray  110  to cover and seal the ice tray  110 , thereby preventing the leakage of water. 
     In a structure that allows water to be supplied to the ice tray  110 , while the ice tray cover  150  covers the ice tray  110 , the ice tray cover  150  may be connected to a drive unit (not shown) and a moving member (not shown) such that the ice tray cover  150  can be linearly moved upward or downward to expose or cover the openings in the ice tray  110 . Consequently, when water is supplied to the ice tray  110 , or when the ice tray  110  is rotated so that ice may be discharged from the ice tray  110 , the ice tray cover  150  may be moved so as to expose the ice tray  110 , so that the water supply or the ice discharge may be carried out. After water has been applied to the ice tray  110 , the ice tray cover  150  may be moved again to cover the top of the ice tray  110 . In certain embodiments, the ice tray cover  150  may be moved linearly upwards to expose the ice tray  110 , and linearly downward to again cover the ice tray  110 , as shown in  FIG. 5 . Other movements may also be appropriate, based on a position of the cover  150  relative to the tray  110 . 
     A lower peripheral edge or a bottom surface of the ice tray cover  150  may correspond to the shape of the top of the ice tray  110 , so that the bottom of the ice tray cover  150  covers and seals the receiving parts  112  of the ice tray  110 . The ice tray cover  150  may be made of a flexible material to allow the ice tray cover  150  to be brought into tight contact with the ice tray  110 , thereby preventing the leakage of water. 
     In the embodiment shown in  FIG. 6 , the ice tray cover  150  may remain stationary relative to the ice tray  110 , with the ice tray cover  150  integrally coupled to the ice tray  110 . For example, the ice tray cover  150  may be molded together with the ice tray  110  by double injection, or may be integrally attached to the ice tray  110  by bonding or welding, depending upon the material of the ice tray cover  150  and the ice tray  110 . 
     When the ice tray  110  is made of a conductive material to which a pulse is applied to separate the ice from the ice tray  110 , the ice tray cover  150  may be made of a nonconductive material. Consequently, when a pulse is applied to the ice tray  110 , the introduction of current to the ice tray cover  150  is prevented, thereby providing for uniform heat generation and dispersion only in the receiving parts  112  of the ice tray  110 , in which the ice is received, while reducing the power consumption. In this case, the ice tray cover  150  may be made of a high heat-resistant material such that the ice tray cover  150  is not deformed or damaged, even when the ice tray  110  is heated. 
     The ice tray cover  150  shown in  FIG. 6  may include a communication part  154  formed at the top of the ice tray cover  150  that allows water to be supplied to the ice tray  110 , as shown in  FIG. 7 . In the alternative embodiments, the communication part  154  may also be formed in an ice tray cover  150  that is rotated about a hinge, as shown in  FIG. 3 , or in an ice tray cover  150  that is moved upward and downward, as shown in  FIG. 5 , such that water may be supplied to the ice tray  110  without the movement of the ice tray cover  150 . 
     The communication part  154  may extend in the longitudinal direction of the ice tray cover  150  (i.e., in the longitudinal direction of the ice tray  110 ) to provide a channel for supplying water to the ice tray  110 . The communication part  154  may also serve as a channel for supplying cool air necessary to freeze water received in the receiving parts  112  of the ice tray  110  during the production of ice. 
     The ice tray cover  150  may also include waterproofing walls  156  extending downward from opposite edges of the communication part  154  to prevent the splashing of water through the communication part  154 . As shown in the sectional view taken along line A-A′ of  FIG. 7 , the waterproofing walls  156  may be inclined toward the center line of the communication part  154  so as to further preclude the splashing water out of the ice tray  110 . In the embodiments shown in  FIGS. 3 and 5 , the ice tray cover  150  is rotated or moved to expose the ice tray  110  to discharge ice from the ice tray  110 . Consequently, the waterproofing walls  156  shown in  FIG. 7  may be sized and inclined so that they do not disturb the discharge of the ice from the ice tray  110 . 
     When the ice tray cover  150  is integrally coupled to the ice tray  110 , as shown in  FIG. 6 , the ice tray  110  and the ice tray cover  150  may be simultaneously rotated to separate the ice from the ice tray  110 . Depending on the size/shape of the ice produced, the size of the communication part  154  and the inclination of the waterproofing walls  156 , the waterproofing walls  156  may disturb the discharge of the ice from the ice tray  110 . Thus, in certain embodiments, the waterproofing walls  156  may be removed, and the communication part  154  may have a size sufficient for the ice to easily pass through the communication part  154  without the ice being caught by the communication part  154 . 
     A control method for an ice maker according to embodiments as broadly described herein will now be described with respect to  FIGS. 8-11 . 
     Such a controlling method may include supplying water to the ice tray  110  through the communication part  154 , formed at the ice tray cover  150 , and freezing the water into ice (S 110 ), rotating the ice tray  110  such that the ice may be separated from the ice tray  110  and fail by virtue of its own weight into a storage bin (S 130 ), heating the ice tray  110  to release a bond between the ice and the ice tray  110  and separate the ice from the ice tray  110  (S 140 ), and then rotating the ice tray  110  back to its original position (S 150 ). 
     To supply water to the ice tray  110 , a control unit (not shown), for controlling the overall function and operation of the ice maker  100 , controls the water supply unit such that water stored in the storage container  132  is supplied to the ice tray  110  through the water supply pipe  134 . The water may be supplied to the ice tray  110  through the communication part  154  formed at the ice tray cover  150 . After the supply of water is completed, cool air may be supplied to the ice tray  110  to freeze the water and produce ice (S 110 ). 
     After the production of ice is completed, the ice tray cover  150  may be moved such that the ice tray  110  is exposed (S 120 ). The ice tray  110  may then be rotated such that the ice falls by virtue of its own weight into a storage bin (S 130 ). 
     In certain embodiments, the ice tray  110  may be rotated after the movement of the ice tray cover  150 . In alternative embodiments, the two steps (S 120  and S 130 ) may be simultaneously carried out. That is, the ice tray  110  may be rotated to the ice separation position (S 130 ) simultaneously with the movement of the ice tray cover  150  (S 120 ). 
     In the embodiment shown in  FIG. 3 , the ice tray cover  150  is hingedly coupled to the main body of the ice maker  100 , and the ice tray cover  150  is rotated about the hinge. Operation of this embodiment of the ice tray cover  150  and the ice tray  110  is shown in  FIGS. 8A-8E . 
     In the embodiment shown in  FIG. 5 , the ice tray cover  150  is moved upward and downward. Operation of this embodiment of the ice tray cover  150  and the ice tray  110  is shown in  FIGS. 10A-10D . 
     In the embodiment shown in  FIGS. 6-7 , the ice tray cover  150  may be integrally coupled to the ice tray  110 . In this embodiment, the ice tray cover  150  and the ice tray  110  are simultaneously rotated to the ice separation position, as shown in  FIGS. 9A-9D . 
     After the ice tray  110  is moved to the ice separation position, the ice tray  110  may be heated to separate the ice from the ice tray  110  and discharge the ice from the ice tray  110  to a storage bin. As previously described, the ice tray  110  may be made of a conductive material exhibiting electrical conductivity, and a pulse may be applied to the ice tray  110  to heat the ice tray  110 . In alternative embodiments, a twist type ice separating system may be used. 
     After the ice separation is completed, the ice tray  110  may be rotated back to its original position (S 150 ). Also, the ice tray cover  150  is moved back to its original position to cover the ice tray  110 . 
     In certain embodiments, the ice tray  110  and the ice tray cover  150  may be simultaneously moved back to their original positions. In this case, the operations of the ice tray  110  and the ice tray cover  150  according to the respective embodiments may be performed in reverse order that which is shown in  FIGS. 8-10 . 
     An ice tray cover  150  as embodied and broadly described herein may effectively prevent the overflow or splashing of water out of the ice tray  110  during the supply of water or when the ice tray  110  is shaken by an external force during the production of ice. 
     Reducing or eliminating this splashing/overflow of water may prevent ice pieces from sticking to each other and a subsequent lowering of freezing efficiency of the ice maker, thus enhancing overall reliability of the system and improving user convenience. 
     An ice maker is provided that is capable of preventing the overflow or splashing of water or thin ice to the outside during the supply of water or when the ice tray is shaken by an external force, and a controlling method of the same. 
     An ice maker as embodied and broadly described herein may include an ice tray for receiving water to be frozen into ice, and an ice tray cover positioned above the ice tray for preventing the overflow or splashing of water from the ice tray. 
     The ice tray may be rotatably mounted such that ice, separated from the ice tray, falls by virtue of its own weight. 
     The ice tray cover may be hingedly coupled to one side of a main body of the ice maker such that the ice tray cover can rotate about the hinge to cover or expose the ice tray. In this case, the ice tray cover may also include at least one connection member extending from one side of the ice tray cover, and the tip end of the at least one connection member may be hingedly coupled to the main body of the ice maker. 
     The ice tray cover may move upward or downward to expose or cover the ice tray. 
     The ice tray cover may be stationary, or the ice tray cover may be integrally coupled to the ice tray. 
     The ice maker may also include a communication part formed at the top of the ice tray cover for allowing water to be supplied to the ice tray therethrough, and waterproofing walls extending downward from opposite edges of the communication part for preventing the splashing of water through the communication part. In this case, the waterproofing walls are preferably inclined toward the middle line of the communication part. 
     A controlling method of an ice maker as embodied and broadly described herein may include supplying water to an ice tray through a communication part, formed at an ice tray cover, and freezing the water into ice, rotating the ice tray such that the ice, separated from the ice tray, falls by virtue of its own weight, heating the ice tray to separate the ice from the ice tray, and rotating the ice tray, from which the ice has been separated, back to its original position. 
     The controlling method may also include moving the ice tray cover to expose the ice tray, in which the ice production is completed, and moving the ice tray cover back to its original position to cover the ice tray, from which the ice has been separated. 
     The ice tray cover may be hingedly coupled to a main body of the ice maker such that the ice tray cover can rotate about the hinge. 
     The ice tray cover may move upward and downward. 
     The ice tray may exhibit electric conductivity, and the heating of the ice tray may be accomplished by applying a pulse to the ice tray. 
     Any reference in this specification to “one embodiment,” “an embodiment,” “example embodiment,” “certain embodiment,” “alternative embodiment,” etc., means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment as broadly described herein. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to effect such feature, structure, or characteristic in connection with other ones of the embodiments. 
     Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various numerous variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.