Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a continuation application of U.S. application Ser. No. 11/140,096 filed May 27, 2005 which claims priority under U.S. application Ser. No. 11/028,422 filed Jan. 3, 2005, entitled REFRIGERATOR WITH FORWARD PROJECTING DISPENSER which application is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The present invention relates generally to refrigerators and more particularly to ice and water dispensers located on the outer surfaces of the doors of refrigerators. As is well known, a refrigerator may be provided with an ice dispenser and a water dispenser. Such dispensers typically are mounted in a front panel of a refrigerator door. In a side-by-side refrigerator, the dispenser generally is located in the freezer compartment door. Each dispenser typically has a lever, actuator button, or actuator pad disposed at the rear most surface of the housing into which a glass or cup can be inserted for filling. A glass may be pressed against the actuation button, pad, or lever, thus activating the dispensing of water or ice cubes, as desired.  
         [0003]     Typically, the dispenser has a cavity that is inset into a door of the refrigerator. The inset cavity of the dispenser takes up valuable storage space within the inner compartment. This storage space is further compromised when an actuator and other circuitry is located at the rear side of the dispenser cavity.  
         [0004]     Additionally, dispensers located within a door compartment have a cavity which receives only limited size beverage containers. For example, a typical water and ice dispenser can receive a beverage glass that holds 12-16 ounces of fluids but not a thermos, cooler, or large capacity beverage glass such as a 48-ounce or 64-ounce cup.  
         [0005]     Dispensers typically have another problem with showering the user with ice chips and water spray when the dispenser is being used. This is mostly due to the fact that an ice chute and water tube are located out of sight up above the control panel for the dispenser and therefore a user cannot see exactly where to locate the container which is to be filled. Then, ice chips or water spray splatters about. Thus, it is desirable to have a dispenser which reduces splattering ice chips and water and helps the user to determine proper location of the container for dispensing.  
         [0006]     Another problem with typical dispensers is that the ice chute door is typically opened and closed with an electrical solenoid. The solenoid is usually relatively noisy, creating an electric buzz or snap sound as the solenoid actuates, causing the dispenser door to open or close. Additionally, solenoids have a relatively high power consumption. Therefore, it is desirable to have an ice chute door which is operable with less power consumption, and less noise.  
         [0007]     A further problem with typical dispensers is that they leak air between the ice box and the ice chute. This is mostly because of manufacturing variances in parts. This in turn causes cold air loss, and moisture/ice buildup. Therefore, it is desirable to reduce air leak between the ice chute and the ice box.  
         [0008]     Thus, a primary objective of the present invention is the provision of an improved water and ice dispenser for a refrigerator.  
         [0009]     Accordingly, one feature or advantage of the present invention is the provision of an ice and water dispenser that allows for increased storage capacity behind the ice and water dispenser.  
         [0010]     Another feature or advantage of the present invention is the provision of an ice and water dispenser that accommodates large cups, water bottles, pitchers, thermoses, coolers, etc.  
         [0011]     Another feature or advantage of the present invention is the provision of an ice and water dispenser which helps a user to locate the receiving container in the proper location and also helps to reduce splatter or spray of ice chips or water on the user.  
         [0012]     Another feature or advantage of the present invention is the provision of an ice and water dispenser that has a lower power consumption and a quieter ice chute door.  
         [0013]     Another feature or advantage of the current invention is reduced air leak between the ice chute and the ice box.  
         [0014]     One or more of these or other features or advantages will become apparent from the following specification and claims.  
       SUMMARY OF THE INVENTION  
       [0015]     The present invention is directed towards a refrigerator with a forward projecting ice and water dispenser attached to the front panel of a refrigerator door. In general, the door of the invention includes an outer door pan, an inner door liner, an ice chute extending through the door, and a dispenser engaging the ice chute. The refrigerator door of the present invention has an outer door cavity and an inner liner cavity.  
         [0016]     One feature of the present invention is an ice chute that is in both the liner cavity and the outer door cavity. This positioning of the ice chute permits the dispenser to be placed forward the front panel of the door to receive ice from the ice chute.  
         [0017]     A further feature of the present invention is a more efficient utilization of storage space upon the inner liner. The forward projecting dispenser makes unnecessary a deep dispenser cavity in both the outer door and the inner liner which necessitates a deep inner liner cavity to accommodate the dispenser protruding into the door.  
         [0018]     A further feature of the invention is the ability to permit oversized cups, water bottles, pitchers, coolers, thermoses, etc. being filled more easily as they do not need to fit within a cavity protruding into the refrigerator door. One problem typically encountered with filling oversized containers is a drip tray interfering with the positioning of the oversized container underneath the ice and/or water dispenser. Therefore, a feature of the present invention is a retractable drip pan adjacent the front panel of the refrigerator door or removable from the front panel. Additionally, the drip tray may be independent the dispenser and attached by a magnet or other attachment means which may be moved when oversize containers are being filled.  
         [0019]     A further feature of the invention is a dispenser with a retracting ledge moveable between a first position and a second position which can be used for holding or supporting containers in shallow dispensers. The retracting ledge can then be moved out of the way when not needed.  
         [0020]     A further feature of the present invention is a dispenser with an angled back side. Having an angled back side, allows more storage space inside the refrigerator compartment along the door.  
         [0021]     A further feature of the present invention is a lighted dispenser target ring extending at least partially around the water tube and the ice chute. The lighted dispenser target ring allows a user a target area for locating the receiving container during dispensing and additionally helps to block oversprayed water or ice chips.  
         [0022]     A further feature of the present invention is an ice and water dispenser with an ice chute door openable with an electric motor. The electric motor rotates a cam which in turn flips open the ice chute door. This allows for quieter opening of the ice chute door and less power consumption during opening of the ice chute door over standard solenoid operated ice chute doors.  
         [0023]     A further feature of the invention is an ice chute air seal between the ice chute and the ice box. This reduces cold air loss from the ice box and therefore reduces moisture/ice buildup.  
         [0024]     Additional objects, features and advantages of the present invention will become more readily apparent from the following detailed description of the 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  
       [0025]      FIG. 1  is a front elevation view of a refrigerator having a forward projecting dispenser with a drip pan included with the dispenser housing.  
         [0026]      FIG. 2  is a side elevation view of the freezer door of  FIG. 1 .  
         [0027]      FIG. 3  is a rear elevation view of a door using a forward projecting dispenser.  
         [0028]      FIG. 4  is a cross sectional view taken along line  4 - 4  of  FIG. 1 .  
         [0029]      FIG. 5  is a front view of a door with a forward projecting dispenser of the present invention with a drip pan independent and removable from the dispenser housing.  
         [0030]      FIG. 6  is a front view of the door of  FIG. 5  with the drip pan removed.  
         [0031]      FIG. 7  is a front view of a door with a forward projecting dispenser without a dispenser cavity.  
         [0032]      FIG. 8  is a side view of the door of  FIG. 7 .  
         [0033]      FIG. 9  is a cross sectional view taken along line  9 - 9  of  FIG. 7 .  
         [0034]      FIG. 10  is a sectional side view of another embodiment of a dispenser in a refrigerator door.  
         [0035]      FIG. 11  is a perspective view looking upwardly from a front side of a dispenser up into the dispensing cavity and the ice chute.  
         [0036]      FIG. 12  is one embodiment of an ice chute actuator assembly.  
         [0037]      FIG. 13  is an exploded view of the actuator assembly of  FIG. 12 .  
         [0038]      FIG. 14  is a perspective view of an inside of a refrigerator door showing an ice chute air seal.  
         [0039]      FIG. 14A  is a side view of a refrigerator showing the ice chute air seal.  
         [0040]      FIG. 15  is a front view of a prior art ice and water dispenser.  
         [0041]      FIG. 16  is a side view of the prior art ice and water dispenser of  FIG. 15 .  
         [0042]      FIG. 17  is a cross sectional view taken along line  17 - 17  of  FIG. 15 . 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0043]     The present invention will be described as it applies to its preferred embodiment. It is not intended that the present invention be limited to the preferred embodiment. It is intended that the invention cover all modifications and alternatives that may be included within the spirit and scope of the invention.  
         [0044]     With reference to  FIG. 1 , a conventional refrigerator  10  is shown, refrigerator  10  being of the side-by-side design, wherein refrigerator  10  has a refrigeration compartment sealed by a refrigerator door  12  and a freezer compartment sealed by a freezer door  14 . One of the doors  12 ,  14  may be provided with a dispenser  16 , generally including a housing  18  defining a dispensing area  22  for an ice chute  20  and water tube  34 .  
         [0045]     Dispenser  16  may utilize ice and/or water selection buttons  28  and an actuator  29 . The user may select water and/or the type of ice to be dispensed such as ice cubes or crushed ice using buttons  28 . The user selects and dispenses ice and water by pressing actuator button  29  that actuates delivery of ice through the ice chute  20  and/or water through the water tube  34 .  
         [0046]     It should be noted that the dispenser  16  could also be found in other types of refrigerators, other than those of side-by-side construction, and thus the dispenser of the present invention, as will hereinafter be described in greater detail, can similarly be used in both refrigerators of side-by-side design, as well as other designs.  
         [0047]     The refrigerator  10  has handles  26  extending outward. The dispenser  16  extends outward from the door  14 . As shown in  FIG. 2  the dispenser may extend approximately level with the handles  26 . Alternatively, the dispenser may extend beyond the handle especially when no dispensing cavity  22  is provided for and as illustrated in  FIG. 8 .  
         [0048]      FIG. 2  illustrates the side of the ice and water dispenser  16 . Dispenser housing  18  frames the control panel  24 , the dispensing area  22 , and a catch tray or drip pan  32 . The control panel  24  and drip pan  32  extend forward the front panel  46  of the outer door panel.  
         [0049]     As seen in  FIG. 2  and  FIG. 3 , the forward projecting dispenser  16  permits the ice chute  20  to be the only structure within an inner liner cavity  44 . In contrast, the prior art as seen in  FIGS. 10-12  require an inner liner cavity  44 A to not only accommodate an ice chute but also the dispenser cavity. Accordingly, the forward projecting dispenser permits a space  40  to be available for a shelf  42 . This extra space  40  is an 11-inch to 12-inch area below the ice chute  20 .  
         [0050]     In general, the doors,  12 ,  14  include an outer door pan  30  and an inner liner  38 . The outer door pan  30  is formed of sheet metal and includes a front panel portion  46 . The door pan  30  can also be constructed of plastic or a combination of metal and plastic. The sheet metal is bent so as to form a top, bottom and opposing side wall portions  48 . Typically, the piece of sheet metal is further bent to define a plurality of flange portions (not shown). The inner door liner  38  is thermal formed but could also be injection molded. In any event, inner door liner  38  includes a portion which defines the inner liner cavity. The inner liner  38  attaches to the outer door pan  30  typically at the plurality of flange portions. Insulation foam is then filled into the void defined by the outer door cavity  50  and the inner liner cavity  44 .  
         [0051]     As seen in  FIG. 4 , the ice chute  20  extends through both the liner cavity  44  and the outer door cavity  50 . Storage space is maximized by having the liner cavity  44  partially defined by an angled side  36  that follows the diagonally mounted ice chute  20 . This is different than the prior art as seen in  FIG. 12  which only has the ice chute  20  extending through the liner cavity  44 .  
         [0052]     As further seen in  FIG. 4 , the forward projecting dispenser  16  permits a less deep ice dispenser cavity  22 . As seen in  FIGS. 4, 9 , and  10  the dispenser cavity  22  may have an angled back side or sloped dispensing cavity  23  protruding into the outer door cavity portion of the outer door pan  30 . A drip pan  32  may be placed on the front panel  46  by an attachment such as screws or may be magnetically attached so that it may be removed as seen in  FIGS. 5 and 6 . The drip pan  32  may be removed whenever larger containers or oversized containers are desired to be filled.  
         [0053]      FIG. 10  shows an embodiment of an ice and water dispenser  16  with an angled backside or sloped dispensing cavity  23 . The sloped dispensing cavity  23  is preferably projected no more than one inch from the door pan  30 . While other depth of projections are also within the scope of the invention, deeper projections reduce storage space inside the refrigerator door. The back slope of the cavity  23  is angled upward and inward with respect to an inside of the refrigerator to minimize the space required by the dispensing cavity  22 . This configuration maximizes space available inside of the fresh food or freezer compartment. Thus, the shallow dispensing cavity  23  allows for extra space  40  and therefore an extra shelf or storage bin  42  in the door.  
         [0054]     As seen in  FIGS. 7-9 , an alternate embodiment of the forward projecting dispenser  16  does not utilize a dispensing cavity  22 . The dispenser  16  extends forward from the front panel  46  a distance beyond the handle  26  to accommodate large and oversized containers. Additionally, a depressible actuator  29 A is provided that is pushed inwardly to actuate the dispensing of ice and/or water. The actuator  29 A doubles as a drip pan  32  and catches excess water when it is released for return back into place under the water tube  34 . The actuator  29 A is removable for cleaning.  
         [0055]     The prior art, as seen in  FIGS. 15-17 , only shows the ice chute  20  in the inner liner  38  portion and specifically a liner cavity  44 . The liner cavity is elongated to insulate the dispenser cavity  22 B. The actuator  29 B and related circuitry is at the rear of the cavity  22 B. Also the drip pan  32 B is within the cavity  22 B. As seen most clearly in  FIG. 16 , the dispenser  16 B is approximately flush with front panel  46  as opposed to forward projecting.  
         [0056]     The dispenser  16  includes a retractable ledge  33 , as best seen in  FIG. 10 . The ledge  33  is movable between an extended position shown in  FIG. 10  wherein the front edge is positioned outwardly from the front surface of the door  12  and a retracted position in  FIG. 11  wherein the front edge is flush with the front surface of the door  12 . The ledge  33  is configured as a tray drip pan  32  but does not have to be. The retracting ledge  33  can be temporarily extended from the shallow main dispenser area  22  to accommodate setting a glass, a pitcher, or other container during ice or water dispensing.  
         [0057]     The retracting ledge  33  can be designed to pull out, fold up, fold down, or even be removable. As seen in  FIG. 10 , the retracting ledge  33  slides in a groove  31 . It is preferred that the retracting ledge  33  have a stop (not shown) which prevents the retracting ledge  33  from being easily removed from the dispensing cavity  22 . The groove  31  additionally helps support the retracting ledge  33  when the ledge  33  is supporting a glass, pitcher, or other container during dispensing. The ledge  33  is most useful in dispensers having a shallow dispensing area  22 , however, the ledge  33  can also be used in a dispenser  16  having a deeper dispensing area  22 .  
         [0058]     As best seen in  FIGS. 10 and 11 , the dispenser  16  has a lighted dispenser target  60 . The lighted dispenser target  60  is preferably a light pipe which gathers light from the cavity light, such as light emitting diodes  62 , to provide a lighted ring, or similar device, as a target for a glass in the dispenser cavity  22 . A portion of the light provided to the cavity  22  is captured by a portion of the lighted dispenser target  60  which directs the light around the opening for ice and water into the cavity  22 . The lighted dispenser target  60  also helps to contain ice chips and spray from the user of the dispenser  16 . Since the lighted dispenser target  60  is capturing light from the dispenser light source  62 , it is preferred to be of a transparent or at least translucent material. The shape of the lighted target dispenser  60  is shown as a rounded arc. This shape works best for containing water spray and ice chips, however, any shape can be used. As best seen in  FIG. 11 , the lighted dispenser extends downwardly around or in front of target  60  and the water tube  34  and ice chute  20  so as to protect a user from water or ice spray.  
         [0059]     Prior art dispensers have used lighted actuator arms which provide a target for placement of a glass during use of the dispenser  16 . However, a lighted actuator arm does nothing to help reduce water spray or ice chip splatter.  
         [0060]     As best seen in  FIGS. 12 and 13 , the dispenser  16  has a motorized ice chute door assembly  70 .  FIG. 12  is a perspective view from the back and side of the assembly  70 .  FIG. 13  is an exploded view from the top/front/side of the assembly  70 . A low current draw motor  82  is used to move the ice chute door  21 . The ice chute door  21  substantially closes off the ice chute  20  when not dispensing ice so as to reduce cold air loss from the ice making or storage compartment. The motor  82  opens the ice chute door  21  using a cam  88 . A position switch  92  is provided to register the ice chute door  21  position as “open” or “closed”. An ice chute door hinge  74  and spring  76  biases the ice chute door  21  to a closed position with respect to the ice chute  20 . The motorized ice chute door assembly  70  replaces the commonly used solenoid-opened-ice chute door.  
         [0061]     In the preferred operation, the user operates the motorized ice chute door assembly  70  by pressing a glass, pitcher, or other similar container against an actuator  78  or other switch type device. The actuator  78  is shown to be an arm in  FIG. 10 , but may alternately be a pad, button, or other mechanism. The actuator  78  can activate an ice or water dispenser, along with the opening of the ice chute door  21 .  
         [0062]     In one embodiment, the actuator  78  applies pressure against an actuator switch  80 . This requires little force from a user and thus is capable of allowing soft type containers, such as a Styrofoam cup, to be used with the dispenser  16 . The actuator switch  80  closes an electrical circuit which powers the motor  82 . The motor  82  rotates a motor gear  84  attached to the shaft of the motor  82 . The motor gear  84 , in turn, rotates a worm gear  86 . The worm gear  86  mates with gears on a cam  88 . The cam  88  thus rotates about a cam shaft  89  and is followed by a cam follower  90 . The cam follower  90  follows the peaks and valleys on the cam  80  and is operatively connected to the ice chute door  21 . The ice chute door  21  pivots along the hinge  74  with the cam follower  90  to open the ice chute  20 . Other configurations or gear trains can be used so long as a motor drives them.  
         [0063]     It is preferred that the cam  88  be constructed so that as the cam follower  90  follows the peaks and valleys on the cam  88  so that the ice chute door  21  will open and close with the peaks and valleys of the cam  88 . It is further preferred, but not necessary, that the cam  88  be constructed with a cam notch  91  such that the cam follower  90  locks into place so as to hold the ice chute door  21  open until the container is disengaged from the actuator arm  78 , afterwhich the ice chute door  21  automatically closes. It is preferred that the motorized ice chute door assembly  70  be constructed to enclose the motor  82  with a motor housing cover  94 .  
         [0064]     As the ice chute door  21  opens, it comes in contact with the position switch  92 , which instructs the motor  82  to stop turning when the door reaches the proper location. A delay is provided in the control system of the refrigerator  10  using an intelligent controller, which then permits the motor  82  to release force upon the motor shaft, which in turn, permits the ice chute door spring  76  to close the ice chute door  21 .  
         [0065]     The motorized chute extension door assembly  70  has advantages over a standard solenoid which is used in many dispensers. Some of the benefits include reduced size, better control, permitting a spring biased chute door  21 , lower power consumption, reduced electrical noise, and no door snap sound upon opening as with a solenoid. However, the primary benefit of a motorized ice chute door assembly  70  is reduced power consumption over a standard solenoid opened door at approximately 2 watts versus 20 watts.  
         [0066]     The motorized ice chute door assembly  70  contemplated by this invention, can use any number of gears and/or cams so long as a motor is used for opening the ice chute door  21 .  
         [0067]     The dispenser  16  of the current invention has an ice chute air seal  100 , as seen in  FIGS. 14 and 14 A. The seal  100  is preferred to be made of a flexible material compound including components such as PVC (polyvinyl chloride), TPV (thermoplastic vulcanizate), MPR (melt-processable rubber), TPU (thermoplastic urethane) or TPE (thermoplastic elastomer). Seal  100  can be made of any material providing compression and expansion properties in a form suitable for molding to a mating surface or extrusion in the alternate method of construction. The flexible material compound of which seal  100  is comprised may include additive such as Kemamide (stearyl erucamide) or PTFE (polytetraflouroethylene) to reduce the coefficient of friction and therefore improve wear resistance at the interface  100  of the seal and ice-box cover  106 , or at the interface of the seal  100  and door liner  38  in an alternate method of construction.  
         [0068]     In the present invention, the seal  100  is comprised of a flexible material over-molded upon a rigid plate (not shown) having a wand type cross-section and attached to the inner door liner  38 . The seal  100  may also be comprised of a flexible, extruded wand or multi-cavitied bellows profile and attached by means of a relatively rigid plate (not shown), or by other means to the inner door liner  38 . Alternatively, the seal  100  may be attached to the ice compartment  106  cover. In the preferred embodiment of the invention, the seal  100  is preferred to be attached to the door liner  38  by means of the rigid plate snapping to the top portion of the ice chute  102  with a friction fit. However, the seal  100  may also be attached directly to the inner door liner  38 .  
         [0069]     The height of the seal  100  is sufficient to reduce the sensitivity of the overall design, with regard to the occurrence of an air leak at the breakable junction  104  between the dispenser  16  and an ice compartment  106  located inside the refrigerator  10 , due to manufacturing variation.  
         [0070]     In another embodiment of the seal  100 , springs (not shown) can supply a resistance force around pegs (not shown) which support a plate (not shown) inserted into the door liner  38 . The pegs allow for the swiping motion incurred during opening and closing of the refrigerator door  12 , without displacing the seal  100 . The seal  100  can comprise multiple parts, or can be a single part that stays in place with a friction fit.  
         [0071]     The purpose of the seal  100  is to seal against air leakage at the breakable junction  104 . The door  21  can be opened and closed to gain access to the fresh food compartment  12  or freezer compartment  14  inside the refrigerator  10 . The ice compartment temperature is normally lower than the fresh food compartment temperature and at a higher pressure. The seal  100 , located around a top portion of the ice chute  102 , creates a seal between the ice compartment  106  and the ice chute  20  in order to prevent air from escaping the ice compartment and causing temperature fluctuations, moisture and/or frost buildup. The ice chute air seal  100  can be of any shape or size and is preferred to be replaceable. However, the seal  100  should seal the air gap between the ice chute  20  and the ice compartment  106 .  
         [0072]     Based on the above, it should be readily recognized that the forward projecting dispenser  16  provides an arrangement for dispensing ice and water that enables the door  12  to include additional internal storage space, create the potential for filling oversized containers, reduce power consumption during ice dispensing, and reduce air leakage between the ice chute and the ice compartment more readily than the prior art. Although described with respect to the preferred embodiment of the invention, it should be readily apparent that various changes and/or modifications can be made to the invention without departing from the spirit thereof. In general, the invention is only intended to be limited by the scope of the following claims.

Technology Category: f