REFRIGERATION SYSTEM, ICE MAKER, AND METHODS OF FORMING ICE

TECHNICAL FIELD

The present specification generally relates to ice makers for refrigeration systems, and more specifically, to ice makers configured to produce ice of varying shapes and/or sizes.

BACKGROUND

The production and storage of ice in household appliances, particularly refrigerators and freezers, has long been a feature appreciated by consumers. Traditionally, ice trays have been manually filled with water, frozen, and then twisted or bent to release the ice cubes. As technology has advanced, automatic ice makers have been integrated into refrigerators, providing a more convenient means of producing ice on demand. However, with increasing consumer demand for specialized ice types, such as crushed ice, nugget ice, or ice of various shapes and sizes, there exists a challenge to efficiently produce multiple types of ice in a compact space. Notably, existing refrigeration systems often rely on multiple ice makers driven by separate motors, each with its own control system. This design approach can be cumbersome, expensive, and often inefficient in terms of space utilization within the appliance. Furthermore, the complexity of having multiple motors and control systems not only escalates manufacturing and maintenance costs, but also increases the potential points of failure in the system. Accordingly, a need exists for an improved refrigeration system that can produce multiple types and sizes of ice in an efficient, compact, and cost-effective manner, thereby reducing the complexity of design and potential service issues

SUMMARY

In an embodiment, a refrigeration system is disclosed. The refrigeration system includes a freezer component defined by a top wall, a bottom wall positioned opposite the top wall, a pair of sidewalls extending between the top wall and the bottom wall, a rear wall positioned adjacent the pair of sidewalls, and a door positioned opposite the rear wall and hingedly connected to at least one of the pair of sidewalls. The refrigeration system also includes an ice maker system having a plurality of trays, a plurality of gears fixedly attached to the plurality of trays, a motor positioned within the refrigeration system, and a shaft rotatably coupled to the motor, the shaft including a threaded surface for engaging at least one of the plurality of gears. The plurality of gears include at least a first gear engaged with at least a second gear, such that rotation of the first gear causes rotation of the second gear.

In another embodiment, an ice maker system is disclosed. The ice maker system includes a plurality of trays; a plurality of containers disposed beneath the plurality of trays; a plurality of gears fixedly attached to the plurality of trays; and a motor having a shaft rotatably coupled to the motor, the shaft including a threaded surface for engaging at least one of the plurality of gears. The plurality of gears include at least a first gear engaged with at least a second gear, such that rotation of the first gear causes rotation of the second gear.

In yet another embodiment, a method of forming ice is disclosed. The method includes disposing a plurality of gears on a plurality of trays within a refrigeration system, the plurality of gears including at least a first gear associated with at least a first tray and at least a second gear associated with at least a second tray, the first gear being engaged with the second gear; engaging a plurality of teeth formed on the first gear with a threaded surface of a shaft rotatably coupled to a motor; filling each of the plurality of trays with a liquid; sensing, using at least one sensor, a state of the liquid within each of the plurality of trays; determining, using the at least one sensor, that the liquid within each of the plurality of trays is in a solid state; and activating the motor, such that the first gear rotates in a first direction and the second gear rotates in a second direction, thereby rotating the first tray in the first direction and the second tray in the second direction to dispose of solidified liquid within the first tray and the second tray into separate containers positioned beneath the first tray and the second tray.

These and additional features provided by the embodiments described herein will be more fully understood in view of the following detailed description, in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments set forth in the drawings are illustrative and exemplary in nature and not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments can be understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:

FIG. 1 depicts a perspective view of a refrigeration system including an ice maker system, according to one or more embodiments shown and described herein;

FIG. 2 depicts a perspective view of an embodiment of the ice maker system of FIG. 1, according to one or more embodiments shown and described herein;

FIG. 3 depicts a perspective view of another embodiment of the ice maker system of FIG. 1; and

FIG. 4 depicts an illustrative flow diagram of a method of forming ice, according to one or more embodiments shown and described herein.

DETAILED DESCRIPTION

Embodiments disclosed herein relate to refrigeration systems, ice maker systems, and methods of forming ice. More specifically, the present disclosure relates to a refrigeration system including an ice maker system having a plurality of trays, a plurality of gears attached to the plurality of trays, and a motor having a shaft rotatably coupled to the motor, the shaft including a threaded surface for engaging at least one of the plurality of gears. Rotation of the shaft of the motor may cause rotation of the plurality of trays at varying speeds in varying directions based on the configuration of the plurality of gears.

For example, in these embodiments, the plurality of gears may include at least a first gear associated with at least a first tray and at least a second gear associated with at least a second tray. The first gear may directly engage the second gear, such that rotation of the first gear in a first direction causes rotation of the second gear in a second direction different from the first direction. In other embodiments, the ice maker system may include an intermediary gear disposed between the first gear and the second gear, such that the intermediary gear engages both the first gear and the second gear. In these embodiments, rotation of the first gear in a first direction causes rotation of the intermediary gear in a second direction opposite the first direction, and rotation of the intermediary gear in the second direction causes rotation of the second gear in the first direction. Accordingly, it should be appreciated that altering the number and/or configuration of the plurality of gears and the intermediary gears utilized in the ice maker system may allow for the individualized control of a plurality of trays using a single motor and shaft.

As should be appreciated, traditional refrigeration appliances, including both domestic and commercial refrigerators and freezers, often come equipped with ice-making mechanisms. These mechanisms are essential in providing users with ready-to-use ice, eliminating the need for manual ice tray filling and freezing. As consumer demand has evolved, there has been an increasing desire for ice in varied shapes and sizes, ranging from crushed ice to larger cubes, and even specialized shapes for beverages.

Traditional ice-making mechanisms within refrigeration units typically employ one of two approaches: single ice type systems and multiple motor systems. Single ice type systems include a straightforward design where a single motor and control system drives an ice tray, producing one specific shape or size of ice. In contrast, multiple motor systems cater to the demand for varied ice types, and often include multiple ice makers, with each ice maker producing a different size or shape of ice and including its own dedicated motor and control system.

Although multiple motor systems may be capable of producing ice of varying shapes and sizes, these systems have a number of shortcomings. For example, multiple motors and control systems take up significant space within the appliance, potentially reducing storage capacity or room for other features. Furthermore, the need for multiple motors and control systems drives up manufacturing costs, which may be passed on to consumers. Serviceability of multiple motor systems may also become challenging, as the increased number of components may make it difficult to diagnose issues and perform repairs on the refrigeration system.

Considering the limitations of traditional systems, a need exists for a refrigeration system that provides the versatility of multiple ice shapes and sizes without the drawbacks of increased space consumption, high costs, and serviceability challenges. The disclosed system remedies the issues with traditional systems by utilizing a single motor and control system to operate a number of unique ice trays that are each capable of forming ice in a variety of shapes and sizes.

Embodiments of refrigeration systems, ice maker systems, and methods of forming ice will now be described in additional detail herein. The following will now describe these refrigeration systems, ice maker systems, and methods in more detail with reference to the drawings and where like numbers refer to like structures.

As depicted in FIG. 1, a refrigeration system 10 is depicted. The refrigeration system 10 may include a freezer component 12, which may be defined by a top wall 14, a bottom wall 16, a pair of sidewalls 18 extending between the top wall 14 and the bottom wall 16, a rear wall 20 adjacent the pair of sidewalls 18 and extending between the top wall 14, the bottom wall 16, and the sidewalls 18, and a front wall 22 positioned opposite the rear wall 20. In these embodiments, the front wall 22 may be a door, or any other similar component hingedly or otherwise rotatably coupled to the freezer component 12, such that the freezer component 12 may be accessed by moving the front wall 22 from a closed position to an open position.

As further depicted in FIG. 1, the freezer component 12 may further include support member 24, which may extend between the pair of sidewalls 18 and at least partially between the rear wall 20 and the front wall 22. In these embodiments, the support member 24 may be configured to support an ice maker system 100, as will be described in additional detail herein. Although the ice maker system 100 is depicted as being positioned on the support member 24 of the freezer component 12 in FIG. 1, it should be appreciated that, in some embodiments, the ice maker system 100 may be positioned on the bottom wall 16 of the freezer component 12. Furthermore, in other embodiments, the ice maker system 100 may be fixedly attached to any of the top wall 14, the pair of sidewalls 18, or the rear wall 20, without departing from the scope of the present disclosure.

Referring still to FIG. 1, the ice maker system 100 may further include a plurality of trays 110 and a plurality of containers 120. In these embodiments, the plurality of trays 110 may be secured (e.g., mounted or otherwise) within the freezer component 12 using a plurality of brackets 130. In the embodiments described herein, the plurality of mounting brackets 130 may be fixedly coupled to the freezer component (e.g, the rear wall 20, the pair of sidewalls 18, etc.), while the plurality of trays 110 may be rotatably coupled to the plurality of brackets 130. Accordingly, the plurality of trays 110 may be configured to rotate relative the plurality of mounting brackets 130, as will be described in additional detail herein.

As further depicted in FIG. 1, the ice maker system 100 may further include a plurality of gears 140. The plurality of gears 140 may be fixedly coupled to the plurality of trays 110, such that rotation of the plurality of gears 140 may result in similar rotation of the plurality of trays 110. In these embodiments, the ice maker system 100 may further include a motor 150 and a shaft 152 connected to the motor 150, such that activation of the motor 150 causes the shaft 152 to rotate. As illustrated in FIG. 1, the shaft 152 may be coupled to at least one of the plurality of gears 140, such that rotation of the shaft 152 in a lateral direction (e.g., about the x-axis as depicted in the coordinate axis of FIG. 1) causes the at least one of the plurality of gears 140 to rotate in a direction perpendicular to the shaft 152 (e.g., about the z-axis as depicted in the coordinate axis of FIG. 1). For example, in the embodiments described herein, at least one of the plurality of gears may be a worm gear, while the shaft 152 may be cylindrical shaft including a screw thread for engaging the worm gear. However, it should be appreciated that any shaft and gear combination capable of translating rotational motion from the shaft to at least one of the plurality of gears 140 may be utilized in the disclosed ice maker system 100 without departing from the scope of the present disclosure.

In the embodiments depicted in FIG. 1, the motor 150 may be fixedly secured to and/or within one of the plurality of sidewalls 18 of the freezer component 12. Furthermore, the motor 150 may be communicatively coupled to at least one sensor, which may be utilized to control actuation of the motor 150, and in turn, the shaft 152. Operation of the motor 150 will be described in additional detail herein with reference to FIGS. 2 and 3.

Referring still to FIG. 1, the plurality of containers 120 may be positioned beneath (e.g., in the −y-direction as depicted in the coordinate axis of FIG. 1) the plurality of trays 110. In these embodiments, rotation of the plurality of trays 110 may cause any material (e.g., ice, water, etc.) contained within the trays to be disposed within the plurality of containers 120. In these embodiments, the plurality of containers 120 may be removably positioned within the freezer component 12, such that each of the plurality of containers 120 may be removed from the freezer component when the plurality of containers 120 are filled with material. For example, the plurality of containers 120 may include a plurality of slots and/or rails that align the plurality of containers 120 beneath the plurality of trays 110 while allowing the plurality of containers 120 to be removed from the freezer component 12.

Although not depicted, in other embodiments, the plurality of containers 120 may include an opening through which material may be withdrawn. For example, the plurality of containers 120 may each include a gate, which may be manually and/or electronically actuatable between an open position and a closed position. In these embodiments, materials (e.g., ice) housed within the plurality of containers 120 may be retrieved by moving the gate from the open position to the closed position. Furthermore, in the embodiments described herein, the front wall 22 (e.g., door) of the freezer component 12 may further include at least one gate aligned with and/or coupled to the gates formed on the plurality of containers 120. In these embodiments, it may be possible to retrieve ice from the plurality of containers 120 by opening the gate formed on the front wall 22 of the freezer component, such that the ice within the plurality of containers 120 may be retrieved without opening the freezer component 12. Accordingly, it should be appreciated that, in these embodiments, the plurality of containers 120 may be fixedly coupled and/or positioned within the freezer component 12.

Referring now to FIG. 2, operation of the ice maker system 100 will be now be described in additional detail. As depicted in FIG. 2, the plurality of trays 110 may include a first tray 110a and a second tray 110b, with each of the first tray 110a and second tray 110b including a plurality of cavities 112. For example, the first tray 110a may include a first plurality of cavities 112a, while the second tray 110b may include a second plurality of cavities 112b.

In these embodiments, the shape and/or size of the plurality of cavities 112 may determine the shape and/or size of the ice formed within the plurality of trays 110. For example, in the embodiments described herein, the plurality of cavities 112 may have a spherical shape, a crescent and/or half-moon shape, a cubelet or bullet shape, or any other similar shape, without departing from the scope of the present disclosure. Furthermore, it should be appreciated that each of the plurality of cavities 112 may further vary in size (e.g., volume), as has been described herein.

Referring still to FIG. 2, the first plurality of cavities 112a formed within the first tray 110a may be of a different size and/or shape than the second plurality of cavities 112b formed within the second tray 110b. Accordingly, the varying shapes and/or sizes of the plurality of cavities 112 may allow for the ice maker system 100 to form various shapes and/or sizes of ice simultaneously. Once the ice has been formed, a user may select the particular shape and/or size ice which to retrieve from the ice maker system 100.

Although the plurality of trays 110 depicted in FIG. 2 include a single row of cavities 112, it should be further appreciated that, in some embodiments, each of the plurality of trays 110 may include a plurality of rows, with each of the plurality of rows including a plurality of cavities 112. In these embodiments, each of the plurality of rows formed within a single tray may include a plurality of cavities having varying shapes and sizes. However, in other embodiments, it should be appreciated that each of the plurality of cavities formed in each of the plurality of rows formed on a single tray may have the same shape and/or size.

As further depicted in FIG. 2, the plurality of containers 120 may include a single container, or may further include a first container 120a and a second container 120b, such that each of the plurality of trays 110 is associated with a container. For example, as illustrated in FIG. 2, the first container 120a may be positioned beneath the first tray 110a, while the second container 120b may be positioned beneath the second tray 110b (e.g., in the −y-direction as depicted in the coordinate axis of FIG. 2). In these embodiments, utilizing separate containers for each of the plurality of trays 110 may be particularly beneficial when each of the plurality of trays 110 include a plurality of cavities 112 having various shapes and/or sizes. For example, as shown in FIG. 2, the first tray 110a may include a plurality of cavities 112a for forming ice in a first shape, while the second tray 110b may include a plurality of cavities 112b for forming ice in a second shape different from the first shape. By utilizing multiple containers (e.g., first container 120a and second container 120b), it may be possible to ensure that ice of the first shape and ice of the second shape may remain separated, such that a user may more easily access and retrieve ice of a desired shape.

Referring still to FIG. 2, ice formed within each of the plurality of trays 110 may be deposited within the plurality of containers 120 by activating the motor 150, such that the shaft 152 rotates in a transverse direction (e.g., about the z-axis as depicted in the coordinate axis of FIG. 2) and causes each of the plurality of trays 110 to rotate in a lateral direction (e.g., about the x-axis as depicted in the coordinate axis of FIG. 2). In these embodiments, the configuration of the plurality of gears 140 may determine a direction in which each of the plurality of gears 140, and in turn, each of the plurality of trays 110 may rotate, as will be described in additional detail herein.

For example, as shown in FIG. 2, the plurality of gears 140 may include a first gear 140a and a second gear 140b. In these embodiments, the first gear 140 may be fixedly attached to the first tray 110a, such that rotation of the first gear 140a results in similar rotation of the first tray 110a. Similarly, the second gear 140b may be fixedly attached to the second tray 110b, such that rotation of the second gear 140b causes rotation of the second tray 110b.

As shown in FIG. 2, the first gear 140a may include a plurality of teeth 142, which may be configured to engage a threaded surface 154 disposed about the shaft 152. Accordingly, when the motor 150 is activated, the plurality of teeth 142 of the first gear 140a may engage the threaded surface 154 of the shaft 152, such that the first gear 140a begins to rotate in a first direction (e.g., a clockwise direction as depicted in FIG. 2).

In these embodiments, the first gear 140a may further include a plurality of perimeter teeth 144, which may be disposed about a circumference of the first gear 140a. As depicted in FIG. 2, the second gear 140b may similarly include a plurality of perimeter teeth 144, with the second gear 140b being rotatably coupled to the first gear 140a via the plurality of perimeter teeth 144 disposed on each of the first gear 140a and the second gear 140b.

Accordingly, in the embodiments shown herein, it should be appreciated that rotation of the first gear 140a in the first direction (e.g., clockwise direction) may result in opposite rotation of the second gear 140b, such that the second gear 140b rotates in a second direction (e.g., counterclockwise direction) opposite the first direction. Furthermore, the interaction between the first gear 140a and the second gear 140b may further allow for equal and opposite rotation of the first gear 140a and the second gear 140b; that is, each of the first gear 140a and the second gear 140b may have an equal radius, such that each of the first gear 140a and the second gear 140b may have the same rotational frequency. In these embodiments, the first tray 110a and the second tray 110b may rotate the same number of degrees in opposite directions, such that ice formed in the first tray 110a and the second tray 110b is deposited within the first container 120a and the second container 120b, respectively, at the same time. It should be appreciated that, by utilizing the plurality of gears 140 described herein, it may be possible to rotate each of the plurality of trays 110 in a desired direction and at a desired angle utilizing a single motor 150 and shaft 152.

Although FIG. 2 depicts the first gear 140a and the second gear 140b as having equal radii, it should be appreciated that, in some embodiments, the first gear 140a may have a first radius that is different from a second radius of the second gear 140b. By adjusting the radius of each of the plurality of gears 140, it may be possible to control that amount that each of the plurality of gears 140 (and in turn, the plurality of trays 110) rotate relative one another.

For example, in embodiments in which the plurality of trays 110 each have a plurality of cavities 112 with varying sizes and/or shapes, each of the plurality of trays 110 may be rotated at different angles in order to deposit ice formed within the plurality of cavities 112 into the plurality of containers 120. In these embodiments, rotating each of the plurality of gears 140 at varying rates may ensure that each of the plurality of trays 110 is sufficiently rotated to dispense ice formed within the plurality of cavities 112, even when each of the plurality of cavities 112 forms ice of varying shapes and/or sizes.

Referring still to FIG. 2, it should be understood that the size and/or shape of ice formed within each of the plurality of cavities 112 may impact the degree to which each of the plurality of trays 110 may be rotated in order for ice to be deposited from the plurality of trays 110 and into the plurality of containers 120. For example, particular shapes of ice may be prone to sticking within the plurality of cavities 112 formed in each of the plurality of trays 110, such that a greater degree of rotation is required to dislodge the ice from the plurality of cavities 112. Similarly, larger ice formations may have a greater surface area in contact with the plurality of cavities 112 formed in the plurality of trays 110, thereby increasing frictional force between the ice and the tray such that a greater degree of rotation is required to dislodge the ice from the plurality of cavities.

Accordingly, in the embodiments described herein, a plurality of gears 140 having different radii may be utilized to ensure that each of the plurality of trays 110 rotate at a desired rate. For example, the ice maker system 100 may include a first gear 140a having a first radius that is smaller than a second radius of a second gear 140b. In these embodiments, because the first radius of the first gear 140 is smaller than the second radius of the second gear 140b, the first gear 140a may revolve at a higher rate than the second gear 140b. As a result, the first tray 110a may rotate more rapidly than the second tray 110b. The gear configuration described herein may be particularly beneficial in embodiments in which ice formed in the first tray 110a is more difficult (and hence, requires more rotation) to dislodge than ice formed in the second tray 110b.

In contrast, in some embodiments, the first gear 140a may have a first radius that is larger than the second radius of the second gear 140b. In these embodiments, it should be appreciated that, because the first radius of the first gear 140a is larger than the second radius of the second gear 140b, the second tray 110b may rotate more rapidly than the first tray 110a. This gear configuration may be particularly beneficial in embodiments in which ice formed within the second tray 110b is more difficult (and hence, requires more rotation) to dislodge than ice formed in the first tray 110a.

Referring still to FIG. 2, and in the embodiments described herein, the plurality of trays 110 may be formed of a flexible material that may aid in depositing ice from each of the plurality of cavities 112 when the plurality of trays 110 are rotated. For example, the plurality of trays 110 may be formed of silicone, plastic, aluminum, rubber, thermoplastic elastomers, or any other similar material without departing from the scope of the present disclosure. Furthermore, it should be understood that each of the plurality of trays 110 may be formed of different materials. For example, in embodiments in which the first tray 110a is configured to mold ice that is more difficult to deposit (e.g., in comparison to the second tray 110b), the first tray 110a may be formed of a material having greater flexibility than the second tray 110b. In these embodiments, the first tray 110a may be subjected to a torsional force (e.g., twisted) to further aid in depositing ice that has been formed within the first tray 110a.

Furthermore, although not depicted, it should be appreciated that the ice maker system 100 depicted in FIG. 2 may include any number of trays, such as two trays, three trays, four trays, or any other number of trays, without departing from the scope of the present disclosure. Similarly, each of the plurality of trays may include any number of cavities, such as four cavities, five cavities, six cavities, or any other number of cavities, without departing from the scope of the present disclosure. In these embodiments, each of the plurality of cavities may further include a different number of cavities (e.g., a first tray may include four cavities while a second tray includes five cavities) as may be necessitated by the size and/or shape of ice formed within each of the plurality of cavities.

Referring still to FIG. 2, each of the plurality of trays 110 may further include at least one sensor 160, which may be communicatively coupled to the motor 150 and to a water inlet valve (not depicted) of the freezer component 12. In these embodiments, the at least one sensor 160 may monitor the state (e.g, solid and/or liquid) and volume of water within each of the plurality of cavities 112 to determine when the motor 150 should be activated in order to deposit ice into the plurality of containers 120, as has been described herein.

For example, as depicted in FIG. 2, the first tray 110a may include a first sensor 160a, and the second tray 110b may include a second sensor 160b. In these embodiments, the first sensor 160a may monitor the state of the water within the plurality of cavities 112 formed within the first tray 110a, while the second sensor 160b may monitor the state of the water within the plurality of cavities 112 formed within the second tray 110b. When the first sensor 160a and/or second sensor 160b determines that the water within the plurality of cavities 112 is sufficiently frozen, the first and/or second sensor 160a, 160b may provide a notification to a controller device to activate the motor 150. Once each of the sensors 160a, 160b provide the notification to the controller device, the motor 150 may be activated to rotate each of the plurality of trays 110 and dispose of the ice formed within each of the plurality of cavities 112.

In these embodiments, it should be noted that the motor 150 may only actuate the plurality of trays 110 when the sensor associated with each of the plurality of trays 110 has indicated that the water within the plurality of cavities 112 is sufficiently frozen. Because the plurality of gears 140 are rotatably coupled, rotation of the first gear 140a (and first tray 110a) may result in similar rotation of the second gear 140b (and second tray 110b). Accordingly, the motor 150 may receive confirmation from each of the sensors associated with each of the plurality of trays 110 prior to activation to ensure that liquid water is not deposited into any of the plurality of containers 120.

Referring still to FIG. 2, and as noted herein, the at least one sensor 160 may be communicatively coupled to a water inlet valve (not depicted), such that the at least one sensor 160 may control a volume of water received by each of the plurality of trays 110. In these embodiments, the water volume in each of the plurality of trays 110 may be manipulated in order to ensure that each of the plurality of trays 110 include a uniform level of ice, even when each of the plurality of trays 110 are used to form ice of varying shapes and/or sizes. It should be appreciated that controlling the volume of water in each of the plurality of trays 110 may further aid in synchronizing the production of ice, such that each of the plurality of trays 110 may be rotated simultaneously without risk of depositing ice in any of the plurality of containers 120.

Turning now to FIG. 3, another embodiment of an ice maker system 100 is disclosed. In the embodiment disclosed in FIG. 3, the plurality of gears 140 may include an intermediary gear 148, which may be used to alternate the direction of rotation of the first and/or second gear 140a, 140b, as will be described in additional detail herein.

As depicted in FIG. 3, an intermediary gear 148 may be disposed between the first gear 140a and the second gear 140b in order to alter the rotational direction of the second gear 140b relative the first gear 140a. For example, as depicted in FIG. 3, the intermediary gear 148 may include a plurality of perimeter teeth 144 configured to engage both the perimeter teeth 144 formed on the first gear 140a and the perimeter teeth 144 formed on the second gear 140b.

Accordingly, when the motor 150 is activated, the interior teeth 142 of the first gear 140a may engage the threaded surface 154 of the shaft 152, such that the first gear 140a rotates in a first direction (e.g., clockwise). In turn, rotation of the first gear 140a in the first direction may cause the intermediary gear 148 to rotate in a second direction opposite the first direction (e.g., counterclockwise). Further still, the rotation of the intermediary gear 148 may cause the second gear 140b to rotate opposite the intermediary gear 148, such that the second gear 140b rotates in the first direction (e.g., clockwise). As a result, in these embodiments, the first gear 140a and the second gear 140b may rotate in the same direction and at the same rate, such that the first tray 110a and the second tray 110b may be rotated in unison. The gear configuration depicted in FIG. 3 may be particularly beneficial in embodiments in which each of the plurality of trays 110 is used to form ice of the same shape and/or size and deposits ice in a common container 120.

As further depicted in FIG. 3, each of the plurality of gears (e.g. first gear 140a and second gear 140b) may include a gear sensor 145. In these embodiments, the gear sensor 145 may be a Hall Effect sensor or other similar encoder which is configured to detect an angle of rotation of each of the plurality of gears. It should be appreciated that, in the embodiments described herein, the gear sensors 145 may be communicatively coupled to the motor 150, such that operation of the motor 150 may be based on the angle of rotation of each of the plurality of gears.

Referring now to FIGS. 1-3, it should be appreciated that the ice maker systems 100 described herein are illustrative in nature, and any combination of trays and/or gears may be utilized in the ice maker system 100 based on the number of trays in the system, the variety of ice being formed within each of the trays, and/or the number of containers utilized in the system. Moreover, it should be appreciated that rotation of each of the plurality of trays 110 may be controlled by adjusting the quantity and/or positioning of the intermediary gears 148.

For example, in the embodiments described herein, a plurality of intermediary gears 148 may be utilized to alter the direction of rotation, speed, or torque of each of the plurality of trays 110. In these embodiments, utilizing an even number of intermediary gears 148 between each of the plurality of gears 140 may ensure that each of the plurality of trays 110 rotate in the same direction. As should be appreciated, each gear in a gear train may reverse the direction of a gear to which it is adjacent. Accordingly, positioning an odd number of intermediary gears 148 between each of the plurality of gears 140 may ensure that each of the plurality of trays 110 rotate in a common direction, while utilizing an even number of intermediary gears 148 between the plurality of gears 140 may ensure that each of the plurality of trays 110 rotate in opposite directions relative each adjacent tray 110. Furthermore, a plurality of intermediary gears 148 may be utilized to control the rate of rotation of each of the plurality of trays 110, as has been described in detail herein with reference to FIG. 2. It should be further understood that, by utilizing a plurality of intermediary gears 148 as described herein, it may be possible to control the rate and/or direction of rotation of any number of a plurality of trays 110 using a single motor 150 and shaft 152, thereby minimizing electricity and space required within the freezer component to form and dispense ice having a variety of shapes and/or sizes.

Although not depicted, it should be further appreciated that, in some embodiments, the ice maker system 100 may include a clutch mechanism, which may be configured to engage and/or disengage individual gears and in turn, individual trays, within the ice maker system 100. In these embodiments, it may be possible to engage and individually rotate a plurality of trays 110 using a single motor 150 but without the use of the intermediary gears 148 described herein.

Turning now to FIG. 4, an illustrative flow diagram of a method 400 of forming ice is disclosed. As depicted at block 410, the method may initially involve disposing a plurality of gears on a plurality of trays within a refrigeration system. In these embodiments, the plurality of gears may include at least a first gear associated with at least a first tray and at least a second gear associated with at least a second tray, with the first gear being engaged with the second gear. By engaging the first gear with the second gear, rotation of the first gear may be translated to rotation of the second gear, as will be described in additional detail herein.

With the plurality of gears disposed on the plurality of trays, a plurality of teeth formed on the at least first gear may be engaged with a threaded surface of a shaft that is rotatably coupled to a motor, as is shown at block 420. With the motor and shaft engaged, the method may advance to block 430, which may involve filling each of the plurality of trays with a liquid, such as water.

When the trays are filled, the method may proceed to block 440, which may include sensing, using at least one sensor, a state (e.g., solid, liquid, etc.) of the liquid within each of the plurality of trays. As depicted at block 450, the method may further involve determining, using the at least one sensor, that the liquid within each of the plurality of trays is in a solid (e.g., frozen) state.

Once the at least one sensor has determined that the liquid is in a frozen state, the method may proceed to block 460, which may involve activating the motor. In these embodiments, activating the motor may cause the first gear to rotate in a first direction and the second gear to rotate in a second direction opposite the first direction. Similarly, because the plurality of gears are fixedly attached to the plurality of trays, rotation of the first gear may cause the first tray to rotate in the first direction, while rotation of the second gear may cause the second tray to rotate in the second direction. As the first tray and second tray rotate, respectively, the frozen liquid (e.g., ice) within each of the trays may be disposed within separate containers positioned beneath the first tray and the second tray.

As should be appreciated in view of the foregoing, a refrigeration system including an ice maker system is disclosed. The ice maker system includes a plurality of trays, a plurality of gears attached to the plurality of trays, and a motor having a shaft rotatably coupled to the motor, the shaft including a threaded surface for engaging at least one of the plurality of gears. Rotation of the shaft of the motor may cause rotation of the plurality of trays at varying speeds in varying directions based on the configuration of the plurality of gears. In these embodiments, the plurality of gears may include at least a first gear associated with at least a first tray and at least a second gear associated with at least a second tray. The first gear may directly engage the second gear, such that rotation of the first gear in a first direction causes rotation of the second gear in a second direction opposite the first direction. In other embodiments, the ice maker system may include an intermediary gear disposed between the first gear and the second gear, such that the intermediary gear engages both the first gear and the second gear. In these embodiments, rotation of the first gear in a first direction causes rotation of the intermediary gear in a second direction opposite the first direction, and rotation of the intermediary gear in the second direction causes rotation of the second gear in the first direction. Accordingly, it should be appreciated that altering the number and/or configuration of the plurality of gears and the intermediary gears utilized in the ice maker system may allow for the individualized control of a plurality of trays using a single motor and shaft, such that a variety of ice having unique shapes and/or sizes may be produced by the disclosed refrigeration system.

Further aspects of the embodiments described herein are provided by the subject matter of the following clauses:

Clause 1. A refrigeration system comprising: a freezer component defined by a top wall, a bottom wall positioned opposite the top wall, a pair of sidewalls extending between the top wall and the bottom wall, a rear wall positioned adjacent the pair of sidewalls, and a door positioned opposite the rear wall and hingedly connected to at least one of the pair of sidewalls; and an ice maker system comprising: a plurality of trays; a plurality of gears fixedly attached to the plurality of trays; a motor fixedly attached to at least one of the pair of sidewalls; and a shaft rotatably coupled to the motor, the shaft including a threaded surface for engaging at least one of the plurality of gears; wherein the plurality of gears include at least a first gear engaged with at least a second gear, such that rotation of the first gear causes rotation of the second gear.

Clause 2. The refrigeration system of clause 1, wherein the ice maker system further comprises a plurality of containers positioned beneath the plurality of trays.

Clause 3. The refrigeration system of clauses 1 or 2, wherein the ice maker system further comprises a plurality of mounting brackets for securing the plurality of trays to at least one of the pair of sidewalls, the top wall, or the rear wall of the freezer component.

Clause 4. The refrigeration system of any of clauses 1-3, wherein each of the plurality of trays are rotatably coupled to the plurality of mounting brackets, such that the plurality of trays are configured to rotate relative the plurality of mounting brackets.

Clause 5. The refrigeration system of any of clauses 1-4, wherein each of the plurality of trays further include a plurality of cavities.

Clause 6. The refrigeration system of any of clauses 1-5, wherein the plurality of cavities in each of the plurality of trays have a different shape and/or size.

Clause 7. The refrigeration system of any of clauses 1-6, wherein each of the plurality of gears has an equal radius, such that each of the plurality of gears rotates at the same rate of revolution.

Clause 8. The refrigeration system of any of clauses 1-7, wherein each of the plurality of gears has a different radius, such that each of the plurality of gears rotate at different rates of revolution.

Clause 9. The refrigeration system of any of clauses 1-8, wherein the first gear includes a plurality of teeth that engage the threaded surface of the shaft.

Clause 10. The refrigeration system of any of clauses 1-9, wherein the first gear includes a plurality of perimeter teeth that directly engage a plurality of perimeter teeth formed on the second gear, such that rotation of the first gear in a first direction causes rotation of the second gear in a second direction opposite the first direction.

Clause 11. The refrigeration system of any of clauses 1-10, further including an intermediary gear disposed between the first gear and the second gear, such that the intermediary gear engages the plurality of perimeter teeth of both the first gear and the second gear.

Clause 12. The refrigeration system of any of clauses 1-11, wherein rotation of the first gear in a first direction causes rotation of the intermediary gear in a second direction opposite the first direction, and rotation of the intermediary gear in the second direction causes rotation of the second gear in the first direction.

Clause 13. The refrigeration system of any of clauses 1-12s, further comprising at least one sensor for determining a state of a liquid deposited within each of the plurality of trays.

Clause 14. An ice maker system comprising: a plurality of trays; a plurality of containers disposed beneath the plurality of trays; a plurality of gears fixedly attached to the plurality of trays; and a motor having a shaft rotatably coupled to the motor, the shaft including a threaded surface for engaging at least one of the plurality of gears; wherein the plurality of gears include at least a first gear engaged with at least a second gear, such that rotation of the first gear causes rotation of the second gear.

Clause 15. The ice maker system of clause 14, wherein each of the plurality of gears has an equal radius, such that each of the plurality of gears rotates at the same rate of revolution.

Clause 16. The ice maker system of clauses 14 or 15, wherein each of the plurality of gears has a different radius, such that each of the plurality of gears rotate at different rates of revolution.

Clause 17. The ice maker system of any of clauses 14-16, wherein the first gear includes a plurality of teeth that engage the threaded surface of the shaft.

Clause 18. The ice maker system of any of clauses 14-17, wherein the first gear includes a plurality of perimeter teeth that directly engage a plurality of perimeter teeth formed on the second gear, such that rotation of the first gear in a first direction causes rotation of the second gear in a second direction opposite the first direction.

Clause 19. The ice maker system of clause 14, further including an intermediary gear disposed between the first gear and the second gear, such that the intermediary gear engages the perimeter teeth of both the first gear and the second gear, and wherein rotation of the first gear in a first direction causes rotation of the intermediary gear in a second direction opposite the first direction, and rotation of the intermediary gear in the second direction causes rotation of the second gear in the first direction.

Clause 20. A method of forming ice, the method comprising: disposing a plurality of gears on a plurality of trays within a refrigeration system, the plurality of gears including at least a first gear associated with at least a first tray and at least a second gear associated with at least a second tray, the first gear being engaged with the second gear; engaging a plurality of teeth formed on the first gear with a threaded surface of a shaft rotatably coupled to a motor; filling each of the plurality of trays with a liquid; sensing, using at least one sensor, a state of the liquid within each of the plurality of trays; determining, using the at least one sensor, that the liquid within each of the plurality of trays is in a solid state; and activating the motor, such that the first gear rotates in a first direction and the second gear rotates in a second direction opposite the first direction, thereby rotating the first tray in the first direction and the second tray in the second direction to dispose of solidified liquid within the first tray and the second tray into separate containers positioned beneath the first tray and the second tray.

The terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms, including “at least one,” unless the content clearly indicates otherwise. “Or” means “and/or.” As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. It will be further understood that the terms “comprises” and/or “comprising,” or “includes” and/or “including” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof. The term “or a combination thereof” means a combination including at least one of the foregoing elements.

It is noted that the terms “substantially” and “about” may be utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. These terms are also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.

While particular embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, such aspects need not be utilized in combination. It is therefore intended that the appended claims cover all such changes and modifications that are within the scope of the claimed subject matter.

REFRIGERATION SYSTEM, ICE MAKER, AND METHODS OF FORMING ICE

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