Patent Publication Number: US-8522571-B2

Title: Variable capacity ice storage assembly

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention pertains to the art of refrigerators and, more particularly, to a variable capacity ice storage assembly for a refrigerator. 
     2. Description of the Related Art 
     Automatic ice making systems for use in domestic refrigerators are well known. A typical ice making system includes an ice maker mounted within the freezer compartment of the refrigerator and an ice storage receptacle or bin supported beneath the ice maker for receiving the formed ice from the ice maker. The ice maker is commonly mounted within the freezer compartment adjacent the side or rear wall of the freezer compartment such that water and power can be readily supplied to the ice maker. The ice storage receptacle is supported by a shelf or other structure arranged beneath the ice maker within the freezer compartment. The ice storage receptacle generally extends across a significant portion of the freezer compartment and has a front end adjacent the freezer door. U.S. Pat. No. 4,942,979 to Linstromberg et al. is an example of such a prior art ice making system. Alternatively, it is also known to provide a removable ice storage bucket on the door of a freezer compartment, as illustrated in U.S. Pat. No. 6,425,259 to Nelson et al. 
     Conventional ice making systems are designed to produce and maintain a relatively fixed quantity of ice pieces. This leads to the potential problem of ice staleness for consumers who have relatively low ice consumption needs. U.S. Pat. No. 4,835,978 to Cole discloses a common means used to limit the quantity of ice formed by the ice maker. In Cole, an ice quantity sensor, comprising a sensing arm, is periodically lowered into the ice storage receptacle for sensing the amount of ice supplied into the storage receptacle. 
     To avoid the problem of ice staleness, it is desirable to limit the amount of ice available based on individual consumers ice consumption. U.S. Pat. Nos. 3,436,928 and 6,148,624 illustrate past efforts to provide flexibility in the amount of ice stored in an ice bin. More specifically, the &#39;928 patent discloses a vertically telescoping ice receptacle, while the &#39;624 patent discloses a system wherein an ice bucket can be vertically adjusted relative to an ice maker. In addition to other problems, these systems require specialize structure and cannot be utilized with standard pre-existing ice dispensing systems. 
     The present invention addresses the need for a variable capacity storage assembly that can be readily employed without necessitating alterations to pre-existing ice making systems. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a variable capacity ice storage assembly for a refrigerator freezer compartment including an ice sensing system and a removable ice storage bucket positioned below an ice maker. A removable insert is provided that can be placed into the ice bucket by a consumer to alter the ice storage capacity of the ice bucket. More specifically, the insert includes one or more tabs having clips thereon for attaching the insert to one or more side walls of the ice bucket. The tabs are fixed to a main body portion having a first solid deflector extending at a first angle therefrom and a second solid deflector extending at a second angle therefrom. 
     One or more hinges may be utilized to connect various parts of the insert, resulting in a reconfigurable insert that can be utilized in multiple positions. Such a reconfigurable insert may including “locking” hinges, or may be utilized with an ice bucket having multiple slotted retainers for holding the insert in a desired position. 
     In use, the main body portion extends into the storage cavity of the ice bucket, effectively reducing the storage volume of the ice bucket. When utilized in an automatic ice dispensing system employing an ice delivery auger, the insert is configured such that the main body portion of the insert does not interfere with the function of the auger. Thus, the ice storage volume can be adapted to a particular user&#39;s needs, preventing prolonged ice-storage and the development of stale ice. 
     Additional objects, features and advantages of the present invention will become more readily apparent from the following detailed description of preferred embodiments when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         FIG. 1  is a front elevational view of a refrigerator incorporating an ice storing and dispensing assembly with a door-mounted ice bucket and an insert constructed in accordance with a first embodiment of the present invention; 
         FIG. 2  is a partial perspective view of the ice storing and dispensing assembly of  FIG. 1 ; 
         FIG. 3  is a cross-sectional side view of the ice storage and dispensing assembly of  FIG. 1 ; 
         FIG. 4  is a perspective view of a second insert embodiment of the present invention; 
         FIGS. 5   a  and  5   b  show a third insert embodiment of the present invention in two different configurations within a shelf-mounted ice bucket; 
         FIG. 5   c  shows the insert of  FIGS. 5   a  and  5   b  within an ice bucket having slotted inserts; 
         FIG. 6  is a perspective view of an ice storing and dispensing assembly with a side wall mounted ice bucket and a fourth insert embodiment of the present invention; 
         FIG. 7  is a perspective view of a side wall mounting ice bucket and a fifth insert embodiment of the present invention; and 
         FIG. 8  is a perspective view of a side wall mounting ice bucket and a sixth insert embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     With initial reference to  FIGS. 1 and 2 , a refrigerator  10 , defining a side-by-side fresh food/freezer configuration, is provided having a cabinet  12  forming a fresh food compartment  14  and a freezer compartment  16 . Both the fresh food compartment  14  and the freezer compartment  16  are provided with access openings. A fresh food door  18  and a freezer door  20  are hingedly mounted to the cabinet  12  for closing the access openings in a manner well known in the art. 
     An ice making assembly  22  is disposed within the freezer compartment  16  and may be mounted to top wall  24  of the freezer compartment  16  as shown, to a side wall, or on freezer door  20 , with each of these mounting arrangements also being known in the art. Preferably, ice maker assembly  22  takes the form of a conventional ice piece making apparatus and produces generally crescent shaped ice pieces as depicted in  FIG. 3 . The ice makers disclosed in U.S. Pat. Nos. 4,649,717 and 5,160,094, herein incorporated by reference, are illustrative of the type of ice makers which may be used in accordance with the present invention. 
     An ice dispensing system  26 , mounted to the freezer door  20 , is provided below the ice making assembly  22  for receiving ice pieces. The ice dispensing system  26  includes an ice bucket or bin  28 , as well as a lower ice crushing system  30 . When operated, the ice dispensing system  26  transfers ice pieces from the bin  28  through the freezer door  20  whereby ice pieces may be dispensed through a forwardly exposed, external ice dispenser station or area  31 . One of the benefits of such a system is that ice bin  28  is removable from the freezer door. This allows a user to readily dispense a large quantity of ice from the ice bucket  28  into a receptacle, such as an insulated cooler. 
     The ice maker assembly  22  is designed to prevent ice harvesting when the ice storage bin  28  is full of ice pieces, when the door  20  is open, or when the ice bucket is removed from the door. The need for this function is well recognized in the ice maker art and a means for providing this function is described in detail in U.S. Pat. Nos. 4,649,717 and 5,160,094, which are incorporated herein by reference. 
     Any type of conventional ice bucket may be utilized in accordance with the present invention, including auger-type ice bucket  28  illustrated in  FIGS. 2 and 3 . Ice bucket  28  includes a base  40  and an upper body  44 . The upper body  44  has a plurality of vertical walls extending upwardly from the base member  40  including a front wall  48 , side walls  49  and  50 , and a back wall  51 . Together with the base member  40 , the walls  49 - 51  define a storage cavity  60  for collecting ice pieces produced by ice maker assembly  22 . The upper body  44  is preferably formed from a clear plastic material such that the quantity of ice pieces stored within the ice bin  28  can be easily, visually determined, while the base  40  is preferably opaque to hide the dispensing mechanisms contained therein. 
     In one preferred embodiment, ice bucket  28  is utilized with an auger-type ice dispensing system, such as the one described in U.S. Pat. No. 6,425,259, incorporated herein by reference. Additionally, ice bucket  28  may be utilized in conjunction with different ice-sensing systems, including the infrared sensing system described in U.S. Pat. No. 6,314,745, also incorporated herein by reference. In the preferred embodiment shown, ice bucket  28  includes apertures or slots  61  and  62 , which provide a clear path through which an infrared ice-sensing beam can be directed. Turning to  FIG. 3 , storage cavity  60  of ice bucket  28  includes a bottom wall portion  64  having an ice outlet opening  70  through which the ice pieces must pass to be dispensed. Rotatably supported within the ice bucket  28  is an auger  72 . As is known in the art, rotation of auger  72  ensures that ice pieces are free to move downwardly, under the urgings of gravity, towards the ice crushing system  30  such that ice pieces may be dispensed. 
     In general, the above-described structure is known in the art and does not form part of the present invention. Instead, this description is provided for the sake of completeness. The present invention is particularly directed to providing a removable insert to be selectively positioned in ice bucket  28 , thereby allowing a user to selectively alter the capacity of ice bucket  28 . In a first embodiment depicted in  FIGS. 2 and 3 , a removable insert  100  comprises a main body portion  104  including a solid first deflector  108  and a solid second deflector  110  extending there from. Additionally, a first tab portion  114  extends from first deflector  108  in a direction opposite of second deflector  110 . First tab portion  114  includes a first clip  116  adapted to selectively connect insert  100  to one of opposing side walls  49  or  50  of ice bucket  28 . In a preferred embodiment, insert  100  additionally includes a second tab portion  118  incorporating a second clip  120  adapted to selectively connect insert  100  to ice bucket  28 . First and second tab portions  114  and  118  are spaced apart, allowing insert  100  to be attached to side walls  49  or  50  without extending across or otherwise interfering with respective apertures  61  and  62 . Thus, insert  100  may be utilized with an infrared ice-sensing system such as the one described in U.S. Pat. No. 6,314,745. In the first embodiment, clips  116  and  120  are depicted as being snapped over the rim of side wall  50 , thus secure insert  100  to ice bucket  28 . However, clips  116  and  120  may be any known type of clip, such as spring-type clips or clips adapted to frictionally engage a wall of ice bucket  28 , for example. 
     Preferably insert  100  is a one-piece molded plastic insert. However, other suitable materials and constructions may be used without departing from the nature of the invention. Insert  100  may be dimensioned as desired to fit into various sizes of open ice buckets. More specifically, the entire length of insert  100  is preferably sized to extend from the top of a respective wall  48 - 51  of ice bucket  28  to at or near bottom wall portion  64  of storage cavity  60 . The width of insert  100  is preferably sized to extend substantially the entire width between front wall  48  and back wall  51 . When utilized with an auger-type dispensing system as shown in  FIGS. 2 and 3 , insert  100  is shaped such that main body portion  104  does not interfere with the function of auger  72  within ice bucket  28 . 
     As best seen in  FIG. 2 , first deflector  108  projects at a first angle from first and second tabs  114  and  118 , and second deflector  110  projects from first deflector  108  at a second angle, substantially parallel to first and second tabs  114  and  118 . The slope of first deflector  110  deflects or funnels ice dropped from ice making assembly  22  to the bottom of ice bucket  28  and to outlet opening  70 . Thus, when tab portions  114  and  118  are engaged with one of the walls of ice bucket  28 , main body portion  104  extends away from side wall  50 , creating a secondary cavity  122  and effectively reducing the usable volume of storage cavity  60 . When a user wishes to reduce the storage volume of storage cavity  60 , he or she simply places insert  100  within storage cavity  60  and connects first and second tabs  114  and  118  to a select one of side walls  49  or  50 . In this way, an ice bucket  28  having a normal capacity of 10 lbs. of ice will have a reduced capacity of, for example, 7 lbs. of ice. The smaller amount of ice storage will allow for a quicker turn-around of old ice with new ice, and will reduce the instances of stale ice within ice bucket  28 . 
     A second embodiment including an insert  100 ′, as shown in  FIG. 4 , is a slight variation of the first embodiment and includes a main body portion  104 ′ including first and second deflectors  108 ′ and  110 ′, and first and second tab portions  114 ′ and  118 ′ including respective clips  116 ′ and  120 ′. In addition, a curved portion  124  extends from a first deflector  108 ′ to second deflector  110 ′. This configuration allows the size of insert  100 ′ to be increased while maintaining a sufficient distance between the auger  72  and main body portion  104 ′. Furthermore, curved portion  124  provides clearance for ice cubes being moved by the auger  72  and prevents ice cubes from jamming up against insert  100 ′ during movement of the auger  72 . 
     In a third embodiment depicted in  FIGS. 5   a - 5   c , an insert  126  includes first and second deflectors  130  and  131  connected by a first hinge  134 , such as a living hinge. First and second tab portions  136  and  138  may be integrally connected to first deflector  130  or may be hingedly connected thereto by a second hinge  140  as depicted in  FIGS. 5   a - 5   c . Although shown as living hinges, it should be understood that first and second hinges  134  and  140  may be any standard hinge known in the art. 
     First and second clips  142  and  144  are connected to respective first and second tab portions  136  and  138 , and are adapted to selectively attach insert  126  to one of opposing side walls  150  or  152  of a shelf-mounted ice bucket  160 . While shown as separate from first and second tab portions  136 ,  138 , first and second clips  142  and  144  may alternatively be integrally formed therewith. In use, first and second hinges  134  and  140  allow second deflector  131  to extend in a first direction substantially perpendicular to first and second tab portions  136  and  138  as depicted in  FIG. 5   a , or extend in a second direction at an angle with respect to first and second tab portions  136  and  138 , as depicted in  FIG. 5   b . As should be readily understood, when second deflector  131  is a first angle as depicted in  FIG. 5   a , the useable storage volume of insert  126  will be decreased more than it will be decreased when second deflector  131  is at a second angle as depicted in  FIG. 5   b . Thus, a consumer can choose to utilize insert  126  in either configuration depending on the storage volume desired in ice bucket  160 . Additionally, first and second hinges  134  and  140  enable insert  126  to be folded for storage when not in use. 
     The first hinge  134  may be configured to “lock” in place at a desired angle. Alternatively, insert  126  may be utilized in conjunction with an ice bucket  160 ′ that includes multiple slotted retainers  164  as depicted in  FIG. 5   c . Various sized inserts may be utilized with this configuration, or insert  126  may include additional living hinges (not shown) or a telescoping first deflector  130  to enable insert  126  to be reconfigured to fit within the various slotted retainers  164 . In addition, insert  126  may included vertically adjustable first and second tab portions  136  and  138  to allow for repositioning between various slotted retainers  164 . Regardless, slotted retainers  164  allow a user to position insert  126  at one of a plurality of angular positions, thereby providing for varying ice storage volumes within ice bucket  160 ′. 
     In a fourth embodiment depicted in  FIG. 6 , a removable insert  170  comprises a main body portion  174  including a solid first deflector  176  and a solid second deflector  178  extending there from. Additionally, opposing first and second tab portions  180  and  182  extend from first deflector  176  and include respective first and second clips  186  and  188  adapted to attach insert  170  to front and back walls  190  and  191  of a side-mounted ice bucket  200 . As with the third embodiment, insert  170  may include hinges (not shown) connecting first and second deflectors  176  and  178 , or may be of unitary construction. Additionally, although clips  186  and  188  are shown as separate and distinct from respective first and second tab portions  180  and  182 , it should be understood that they may be formed integrally with tab portions  180  and  182 . 
     Still further embodiments of the present invention are depicted in  FIGS. 7 and 8 , respectively.  FIG. 7  depicts a removable block insert  210  including side walls  212 - 215  and a top wall  216 . A dispensing aperture  220  is located in top wall  216  and is defined by an inside wall  224  extending through block insert  210 . Block insert  210  may be solid, or may be a hollow shell defined by walls  212 - 216  and inside wall  224 . Regardless, block insert  210  is preferably sized to extend substantially the entire length and width of ice bucket  200 , and extend to a height less than the height of ice bucket walls  190 - 193 . In this manner, block insert  210  reduces the volume of the ice buckets storage cavity  226 , while allowing ice to fall through dispensing aperture  220  to an external ice service area, such as service area  31  depicted in  FIGS. 1 and 3 . When utilized with an auger-type dispensing system as shown, block insert  200  is sized and configured such that an auger  72 ′ may extend through aperture  220 , and block insert  200  does not interfere with the function of auger  72 ′ within ice bucket  200 . 
     A generally similar, removable curved insert  300  is depicted in  FIG. 8 , and includes a top wall  302  having first and second scooped portions  304  and  306 , and a dispensing wall  308  defining a dispensing aperture  310  that extends through top wall  302 . First and second scooped portions  306  and  308  are preferably curved to direct ice dispensed into ice bucket  200  into dispensing aperture  310 . Additionally, top wall  302  of scoop insert  300  is preferably sized to extend substantially the entire length and width of ice bucket  200 , and extend to a height less than the height of walls  190 - 193 . In this manner, scoop insert  300  reduces the capacity of storage cavity  226 , while allowing ice to fall through dispensing aperture  310  to external an ice service area, such as ice service area  31  depicted in  FIGS. 1 and 3 . Additionally, insert  300  is sized such that auger  72 ′ may extend through aperture  310  without insert  300  interfering with the function of auger  72 ′ within ice bucket  200 . 
     Although various ice bucket embodiments are depicted and described, it should be understood that the inserts of the present invention are intended for use in a variety of standard ice buckets and should not be limited to those ice bucket configurations discussed herein. Additionally, although described with reference to preferred embodiments of the invention, it should be readily understood that various changes and/or modifications can be made to the invention without departing from the spirit thereof. For instance, the particular structure utilized to attach a given insert to an ice bucket may be varied without departing from the spirit of the invention. In general, the invention is only intended to be limited by the scope of the following claims.