Patent Publication Number: US-8109112-B2

Title: Variable ice storage assembly and method of use

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention pertains to the art of ice making in refrigerators and, more particularly, to a variable ice storage assembly within a refrigerator, as well as its method of use. 
     2. Discussion of the Related Art 
     Automatic ice making systems for use in domestic refrigerators is 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 a prior art ice making system. 
     It is known to prevent an ice maker assembly from sending ice cubes to a storage bin when the storage bin is not positioned to receive ice. In one proposed solution as set forth in U.S. Pat. No. 6,438,976, a bin detection sensor, such as an inductive or optical sensor, is used to sense the presence of the storage bin. 
     Another aspect of conventional ice making systems is that they produce a fixed quantity of ice pieces. This leads to the 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, constituted by a sensing arm, is periodically lowered into the ice storage receptacle for sensing the amount of ice supplied into the storage receptacle. An alternative ice sensing method is set forth in U.S. Pat. No. 6,050,097 to Nelson et al., which discloses the use of an electronic optical system for sensing the presence of ice pieces within an ice bucket. However, Cole and Nelson et al. only provide single fixed level sensing systems, which results in a set volume of ice being produced and stored in an ice bucket. 
     To actually 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. 5,619,858 and 4,719,762 illustrate past efforts to provide flexibility in the amount of ice produced and supplied to an ice bin. 
     The present invention addresses the need for easy delivery of fresh ice remotely from the refrigerator by providing a method and apparatus for selectively limiting the amount of ice dispensed into a variable ice storage assembly. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a variable ice storage assembly for a refrigerator. The refrigerator includes an ice maker within a freezer compartment of the refrigerator, and a variable ice storage assembly including a storage cavity adapted to receive ice dispensed from the ice maker, with the amount of ice stored being selectively adjustable. In one preferred embodiment of the invention, an inductive sensor is positioned in the refrigerator to indicate the presence of the storage assembly in the freezer compartment in order to control the formation and dispensing of ice. 
     The storage assembly includes first and second insert portions positioned adjacent respective opposing side walls of the storage assembly. The storage assembly can be utilized in a non-reflecting configuration when the first and second insert portions remain empty, or a reflecting configuration when first and second mirrored inserts are positioned in the first and second insert portions respectively. The storage assembly is positioned between an infrared (IR) emitter located on a first inside wall of the refrigerator and a receiver positioned on an opposing inside wall of the refrigerator. When the storage assembly is in the non-reflecting configuration, an emitted IR beam travels in a direct line to the receiver of the overall IR sensor. Any interruption of the beam by ice at a particular level within the storage assembly signals the ice maker to stop ice production. When the storage assembly is in the reflecting configuration, the first and second mirrored inserts direct the IR beam in a circuitous path that effectively lowers the level of ice sensed by the IR sensor within the storage assembly. More specifically, the emitted IR beam reflects off the first mirrored insert and is directed to a first reflecting plate within the storage cavity. The first reflecting plate directs the beam across the storage cavity to a second reflecting plate which, in turn, directs the beam to the second mirrored insert, where the beam is finally reflected toward the receiver. Multiple angled slot pairs within the respective first and second insert portions allow a user to insert the first and second mirrored inserts at a variety of angles within the storage assembly. Various angles correspond to distinct ice volume levels within the storage assembly, allowing a user to selectively limit the amount of ice available based on the user&#39;s ice consumption. 
     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 DRAWINGS 
         FIG. 1  is a front elevational view of a refrigerator apparatus incorporating an ice dispensing system with a variable ice storage assembly constructed in accordance with the present invention; 
         FIG. 2  is a partial perspective view of the freezer compartment inside the refrigerator of  FIG. 1 , including the ice dispensing system with a variable ice storage assembly; 
         FIG. 3  is a left side view of the ice dispensing system and variable ice storage assembly of  FIG. 2 ; 
         FIG. 4   a  is an exploded perspective view of an alternative embodiment of the variable ice storage assembly of the present invention; and 
         FIG. 4   b  is a perspective view of the variable ice storage assembly of  FIG. 4   a  in a reflecting configuration. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     With initial reference to  FIGS. 1 and 2 , a refrigerator  10 , comprising a side-by-side fresh food/freezer configuration, includes 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 , such as being mounted to the inside surface of a top wall  24  of the freezer compartment  16  as shown. Regardless, at this point, is should be recognized that ice making assembly  22  can be mounted at a wide range of locations in freezer compartment  16 . Preferably, ice maker assembly  22  is a conventional ice making apparatus which forms 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 maker used in 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 a variable ice storage assembly  28 . In the first embodiment shown in  FIGS. 1-3 , storage assembly  28  is in the form of an ice storage bin  29  including an ice crushing system  30 . When operated, the ice dispensing system  26  transfers ice pieces from the storage assembly  28  through the freezer door  20 , whereby ice pieces may be dispensed through a conventional, forwardly exposed ice dispenser station or service area  31 . One of the benefits of such a system is that storage assembly  28  is removable from the freezer door. This allows a user to readily dispense a large quantity of ice from the storage assembly  28  into a receptacle, such as an insulated cooler. 
     The ice maker assembly  22  is designed to prevent ice harvesting when the storage assembly  28  is full of ice pieces, when the door  20  is open, or when ice storage bin  29  is removed from the door  20 . 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. Preferably, an inductive sensor is utilized in order to sense the presence of storage assembly  28  on door  20 . In the embodiment shown in  FIG. 3 , a wire coil  34  is incorporated into door  20  of the refrigerator  10  and connected to inductance sensing circuitry indicated at  36 . A ferrous metal plate  38  on or in storage assembly  28  causes a measurable change in inductance of wire coil  34  when metal plate  38  is proximal to wire coil  34 . Alternatively, the ice bucket sensing apparatus may include a capacitive sensor rather than an inductive sensor. In another alternative arrangement, a reed switch and magnet sensing system (not shown) may be utilized. In this arrangement, the reed switch is preferably located within the refrigerator and either opened or closed by a magnet arranged on or in storage assembly  28 . For instance, a magnet can be incorporated into base  40  of storage assembly  28  to actuate a reed switch located in freezer door  20 . The status of the reed switch indicates the presence of storage assembly  28 . At this point, it should be understood that the ice bucket sensor could be positioned in a variety of places within refrigerator  10  and should not be limited by the embodiments shown herein. 
     As best seen in  FIG. 2 , storage assembly  28  includes a base  40  and an upper body  44 . The upper body  44  has a plurality of vertical walls which extend upwardly from the base member  40  and include a front wall  48 , side walls  49  and  50 , and a back wall  51 . Together with the base member  40 , the walls  48 - 50  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 storage assembly  28  can be easily, visually determined, while the base  40  is preferably opaque to hide the dispensing mechanisms contained therein. 
     Storage assembly  28  may be utilized with an auger-type ice dispensing system, such as the one described in U.S. Pat. No. 6,425,259, also incorporated herein by reference. Turning to  FIG. 3 , storage assembly  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 storage assembly  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 force of gravity, to the ice crushing system  30  such that ice pieces may be dispensed. 
     Additionally, storage assembly  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 incorporated herein by reference. In general, light (electromagnetic radiation of any wavelength) is used to sense the presence of ice pieces. More specifically, an optical ice level sensing system takes advantage of the fact that ice pieces formed by a conventional ice maker, as described above, have a cloudy core which is due to air bubble entrapment caused during the freezing process, and water impurities among other things. This cloudy core of the ice pieces blocks a wide range of wave lengths that are generated and sensed by many standard infrared (IR) radiation products. In a preferred embodiment shown, storage assembly  28  includes apertures  80  and  81 , which provide a clear line of sight between a light emitter  90  and a receiver  92  of an ice level sensor. Light emitter  90  is preferably mounted on side wall  21  of the freezer compartment  16  adjacent the top of the storage assembly  28 , while the receiver  92  is mounted to a side wall  23  of the freezer compartment  16  opposite from the emitter  90 . A microprocessor (not shown) controls the operation of the ice level sensing system. 
     Reference will now be made to  FIGS. 2 and 3  in detailing certain inventive structure of storage assembly  28 . In the first embodiment shown, storage assembly  28  includes a first insert portion  100  adjacent side wall  49  and a first stationary reflecting plate  102  extending from side wall  49  below aperture  80 . Additionally, a second insert portion  106  is located adjacent side wall  50  and a second stationary reflecting plate  108  extends from side wall  50 . First and second mirrored inserts  110  and  111  are adapted to be removably inserted into insert portions  100  and  106  respectively. Insert portions  100  and  106  include multiple angled slot pairs  120  and  126 . More specifically, multiple sets of opposing slots  120  and  126  are formed along side walls  48  and  51  of storage assembly  28 , and each set of opposing slots  120  and  126  is adapted to support a respective mirrored insert  110 ,  111  therein at a specific angle with respect to emitter  90  and first and second reflecting plates  102  and  108 . It should be understood that stationary reflecting plates  102  and  108  are configured to reflect IR radiation when first and second mirrored inserts  110  and  111  are in any of the possible angled positions. Each angled position of mirrored inserts  110  and  111  allows for a different reflected height of IR radiation through storage cavity  60 . Storage assembly  28  thus lowers the ice level sensed within storage cavity  60 , thereby signaling ice maker  22  to stop ice production at a desired ice volume level. The preferred method of use will be discussed in more detail below with reference to the second embodiment of the present invention. 
     Turning now to  FIGS. 4   a  and  4   b , an alternative variable ice storage assembly is shown, wherein variable ice storage assembly is in the form of a removable insert  130  including side walls  134 - 137 , and optionally, a bottom wall  138 . Insert  130  is adapted to be positioned within an ice bucket  140  including side walls  144 - 147  and a bottom wall  148 . Additionally, removable insert  130  includes a first insert portion  200  adjacent side wall  135  and a first stationary reflecting plate  202  extending from side wall  135  below an aperture  203 . Additionally, a second insert portion  206  is located adjacent side wall  137  and a second stationary reflecting plate  208  extends from side wall  137  below an aperture  209 . First and second mirrored inserts  210  and  211  are adapted to be removably inserted into respective insert portions  200  and  206 . Insert portions  200  and  206  include multiple angled slots  220  and  226 , which allow first and second mirrored inserts  210  and  211  to be positioned at various angles within respective insert portions  200  and  206 . It should be understood that stationary reflecting plates  202  and  208  are configured to reflect IR radiation when first and second mirrored inserts  210  and  211  are in any of the possible angled positions. Each angled position of mirrored inserts  210  and  211  allows for a different reflected height of IR radiation through a storage cavity  60 ′ of insert  130 . 
     When a user wishes to utilize removable insert  130 , the user simply positions insert  130  within a storage cavity  230  of ice bucket  140 . As depicted in  FIG. 4   a , storage cavity  230  is defined by side walls  144 - 147  and a bottom wall  148 . In the non-reflecting configuration shown in  FIG. 4   a , IR radiation generated by light emitter  90  is directed along path  250  through storage cavity  230  to receiver  92 . As discussed above, when ice pieces reach a certain volume within storage cavity  230 , the ice pieces will impede the transmission of the IR radiation, signaling the ice making assembly  22  to stop ice production. 
       FIG. 4   b  depicts the storage assembly in a reflecting configuration, wherein mirrored inserts  210  and  211  are placed into respective insert portions  200  and  206 . When insert  130  is positioned within storage cavity  230 , apertures  260  and  261  of ice bucket  140  align with respective apertures  203  and  209  of insert  130 . With this configuration, an IR beam originating from emitter  90  has a clear path to mirrored insert  210 . In this configuration, IR radiation generated by light emitter  90  is directed along a circuitous path  270 . More specifically, IR radiation reflects off mirrored insert  210  and is directed to stationary reflecting plate  202 , where it is reflected across storage cavity  60 ′ to stationary reflecting plate  208 . In turn, stationary reflecting plate  208  reflects the IR radiation up to mirrored insert  211  where it is reflected toward light receiver  92 . It should be understood that stationary reflecting plates  202  and  208  are configured to reflect IR radiation when mirrored inserts  210  and  211  are in any of the various, possible angled positions. Each angled position of mirrored inserts  210  and  211  allows for a different reflected height of IR radiation through storage cavity  60 ′, thereby enabling a user to choose the optimal amount of ice stored in the storage assembly. In other words, this configuration essentially lowers the effective height of the sensor within storage cavity  60 ′, thereby signaling ice maker  22  to stop ice production with a smaller volume of ice present in ice bucket  140  then when the system is in the non-reflecting configuration. 
     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, although shown only in conjunction with the first embodiment of the present invention, it should be understood that the inductive sensing system discussed above may also be utilized with alternative embodiments of the present invention. In general, the invention is only intended to be limited by the scope of the following claims.