Patent Application
20090255279
1. Field
The patent disclosure relates to a refrigerator.
2. Background
A refrigerator refrigerates or freezes food items or the like to keep them fresh in storage. The refrigerator includes an ice maker for making ice and an ice container to receive ice made by the ice maker.
A full ice detection lever, a mechanical device, coupled to a controller detects whether or not the ice container is full of ice. The full ice detection lever is positioned at a lower side and rises as high as the ice is accumulated in the ice container. When the full ice detection lever rises by mote than a certain height due to ice accumulation, the controller determines that the ice container is full.
However, in the related art, if the full ice detection lever becomes frozen, the mechanical operation of the full ice detection lever is not likely to be performed, and the controller cannot determine whether the ice container is full. In such faulty state, ice is continuously supplied, causing an overflow of ice from the ice container.
An ice detecting apparatus of an ice maker disposed to make ice in a refrigerator includes an ice maker and an ice detecting sensor to detect an ice-full state of ice storage container. The ice detecting sensor may be disposed at the ice maker. The ice detecting sensor may also be heated by a heater.
The embodiments will be described in detail with reference to the following drawings in which like reference numerals refer to like elements wherein:
A dispenser 190 supplies ice kept in the ice container 180 upon user demand. One of ordinary skill in the art can appreciate that the refrigerator 10 includes various components such as a compressor, a condenser, an expander, an evaporator, and the like, to form a refrigerating cycle. The refrigerating chamber 11 and the freezing chamber 12 are accessed using a refrigerating chamber door 13 and a freezing chamber door 14, rotatably attached to the housing.
After a prescribed amount of water is supplied to the ice maker 100, ice is made by the supplied cooling air in the ice maker 100, and the ice is separated from the ice maker 100 according to a self-operation of the ice maker 100. The ice falls into the ice container 180 so as to be collected therein. The ice collected in the ice container 180 is supplied to the user by a desired amount through the dispenser 190. As can be appreciated, the ice maker 100 may be installed inside the freezing chamber 12 rather than on the door 14.
A water supply unit 107 of an ice maker 100 receives water provided from the exterior, and ice is made in an ice making chamber 104 of an ice maker 100. An ejector 105 of an ice maker 100 separates ice made in the ice making chamber 104, and an ice maker body 101 of an ice maker 100 includes a plurality of components for rotating the ejector 105. A rotational shaft extends out of the ice maker body 101. The ejector 105 has portions (or arms) extending outwardly (or radially) from the shaft and rotates according to a rotational movement of the shaft in order to pick up ice.
A mounting unit or plate 102 is formed behind the ice making chamber 104 to mount the ice maker 100 within the refrigerator. Holes 103, into which a combining protrusion is inserted, allow the mounting unit 102 to be mounted on the door or within the freezing chamber.
A separator 106 is formed at an upper portion of the ice making chamber 104 to allow ice to be picked up by the ejector 105 to be guided and fall into the ice container 180.
A heater 140 is installed at a lower portion of the ice making chamber 104 in order to apply heat to allow the interfaces of ice and an inner surface of the ice making chamber 104 to be separated from each other. The heater 104 may be electrically connected to an external power source, which may be provided within the ice maker body 101.
A heater support 130 may be formed at a lower portion of the ice making heater 140. The heater support 130 may be connected with the ice maker body 101, or the heater support 130 may be molded together with the ice maker body 101.
In this embodiment, a sensor housing 110 extends with a certain length in a downward direction from the ice maker body 101. A portion of the heater support 130 extends up to a position corresponding to the sensor housing 110.
A transmitting unit or module 121 is installed in the sensor housing 110, and a receiving unit or module 123 is installed at a portion extending from the heater support 130 to correspond to the sensor housing 110 or the transmitting unit 120. A transmitter 122 and a receiver 124 for transmitting and receiving signals are installed in the transmitting unit 121 and the receiving unit 123, respectively, to face each other. Based on the transmitting and received signals, the transmitting unit 121 and the receiving unit 123 are used to detect an ice-full state of the ice container 180. An ice detecting sensor 120 comprises at least one of the transmitter 122 and the receiver 124, transmitting and receiving units 121, 123, or sensor housing, and is used to determine or detect ice full state of the ice container 180.
The ice detecting sensor 120 may be disposed in or near the top, above or below the top of the ice container 180 at a position corresponding to the height at which ice is fully accumulated or collected. The transmitter and/or receiver may be optical devices to transmit or receive IR light. For example, the transmitter or emitter may be an IR photo diode and the receiver may be a photo transistor. The structure of the optical emitter or receiver is disclosed in U.S. Pat. No. 4,201,910, whose entire disclosure is incorporated herein by reference.
As shown in
Although, the position of the transmitter 122 has been described, the receiving unit 123 and the receiver 124 may be formed to correspond to or near the height of the transmitting unit 121 and the transmitter 122, as can be appreciated by one of ordinary skill in the art. In this embodiment, a detection height of the ice detecting sensor 120 may have a certain height difference (h) from an upper end or top ridgeline 181 of the ice container 180.
The transmitting unit 121 and the receiving unit 123 of the ice detecting sensor 120 are located at both sides of an ice discharging outlet, a passage through which ice is discharged from the ice maker body 101. The receiver 124 receives infrared rays transmitted from the transmitter 122, traversing the ice discharging outlet, and provide corresponding signals for determining whether the ice container 180 is substantially full of ice to detect the ice-full state. As can be appreciated, the location of the transmitting module and the receiving module may be reversed, i.e., receiver on the left and emitter on the right.
In this embodiment, the transmitter module and the receiver module are separated by a prescribed distance which is less than a width of the storage bin. Such lesser distance to the width allows the modules to be placed within the storage bin. In an alternative embodiment, the distance may be greater than the width such that the modules may be located outside the storage bin.
A transfer unit 150 is installed at a lower portion of the ice container 180. The transfer unit 150 transfers ice stored in the ice container 180 (crushes the ice into an appropriate size, if desired) through an outlet 160 and a guide path 170 to a dispenser 190.
The transfer unit or assembly 150 includes a fixed blade 155 fixed in the ice container 180, a rotatable blade 151 relatively rotating with respect to the fixed blade 155, a rotational shaft 153 to which the rotational blade 151 is connected, a motor 154 connected to the rotational shaft 153, and a transfer blade 152 to allow the transfer of ice. The rotatable blade 151 is formed at one side of the rotational shaft 153, and the transfer blade 152 is formed at the other side of the rotational shaft. Thus, when the rotational shaft 153 is rotated, the rotational blade 151 and the transfer blade 152 can be rotated together. A spiral auger may be used as the transfer blade 152.
Water is guided by a water supply pipe of a certain shape so as to be supplied to the water supply unit 107. The supplied water is introduced into the ice making chamber 104, and below-zero or near zero cold air is provided in the ice making chamber to freeze water received in the ice making chamber 104. After the water within the ice making chamber 104 becomes frozen, heat is applied toward the ice making chamber 104 by the heater 140 to allow the ice and the contact surface of the ice making chamber 104 to be separated from each other.
The ejector 105 operates by a certain driving mechanism installed in the ice maker body 101 to pick up the ice. After the ice is picked up by the ejector 105, it is guided by the separator 106 and then falls into the ice container 180 for storage. This operation is repeated, and when the ice container 180 is near full or full of ice, the ice detecting sensor 120 detects the ice-full state, and the operation of the ice maker 100 is stopped.
When ice supply to the user via the dispenser 190 is requested, the motor 154 is driven and the rotational shaft 153 connected to the motor 154 is rotated. Then, the rotational blade 151 and the transfer blade 152 are rotated in conjunction. As the transfer blade 152 is rotated, ice in a lower portion of the ice container 180 is transferred toward the rotational blade 151. When the ice guided toward the rotational blade 151 is caught between the rotational blade 151 and the fixed blade 155, it is crushed according to a pushing operation of the rotational blade 151. The crushed ice is dispensed through the outlet 160 formed at a lower side of the fixed blade 155. The dispensed ice falls through the guide path 170. The fallen ice is then supplied to the user via the dispenser 190. As can be appreciated, various components described above are controlled by at least one controller provided in the ice maker and/or the refrigerator, including making a determination of a full-state based on at least one signal received from the receiver.
Various types of ice makers and operations thereof are disclosed in U.S. Pat. Nos. 7,210,299, 7,080,518, 7,017,354, 6,857,279, and 6,705,091, whose entire disclosures are incorporated herein by reference. These patents are also commonly assigned to the same assignee of this application.
Ice made by the ice maker 100 is discharged and falls into the ice storage container 180. The fallen ice is collected and stored within the ice storage container 180. While the ice is collected in the ice container 180, and/or before the ice accommodating container 180 is full of ice, infrared rays transmitted from the transmitter 122 reach the receiver 124, and the controller determines whether the ice container 180 is full of ice based on signals received from or detected by the receiver.
As ice is collected and stored, ice would reach the full or near full height of the ice container 180. Hence, as shown in
In this embodiment, the ice detecting sensor 120 is disposed at the ice maker body 101 and detects full or near full ice collected within the ice container 180. Because the ice detecting sensor 120 can detect a level of ice stored in the ice container 180, the related art problem(s) of a mechanical ice detecting lever (or the like) can be avoided. The ice filled state of the ice container 180 can be more accurately and stably detected.
With reference to
The heater 140 may include linear portions or rods 141 and 143 and a bent/curved portion or rod 142 and a connection plate 144 connecting or integrated with the linear portions 141 and 143. The heat bridge 300 has a step like shape and includes a connection/inclined portion or plate 301, a heater connection portion or plate 302 and a transmitter connection portion or plate 303.
The heater connection plate 302 allows heat at the linear portion 141 to pass therethrough, and surrounds the linear portion 141. The transmitter connection plate 303 allows transfer of heat to the transmitter 122 and surrounds the transmitter 122. The inclined plate 301 connects the heater connection plate 302 and the transmitter connection plate 303. The angle of inclination θ of the inclined plate may be varied depending upon h desired as shown in
Heat generated by the heater 140 can be partially transferred to the transmitter 122 via the heat bridge 300. The surface of the transmitter 122 can be heated by heat delivered from the heater 140, defrosting or preventing frost from forming on the surface of the transmitter 122 and/or receiver 124 (alternatively, transmitter module and/or receiver module). As can be appreciated, the formation of frost on the transmitter 122 and/or receiver 124 hampers the transmission and/or detection of light from the transmitter or the receiver. The heater 140 may be continuously heated while the ice maker 100 is making and discharging ice, and the heat of the heater 140 can be continuously transferred to the ice detecting sensor 120 via the heat bridge 300.
When the ice detecting sensor 120 detects that the interior of the ice container 180 is full or near full of ice, the ice maker 100 stops making and discharging ice, and the operation of the ice making heater 140 may be also stopped. In such an instance, there is a possibility that the receiver and transmitter of the ice detecting sensor 120 may become frosted. In order to defrost the surface of the receiver and transmitter, the controller may operate the heater 140 at certain time intervals to transfer heat to the ice detecting sensor 120 via the heat bridge 300. Accordingly, the ice-full state detecting sensor 140 may be defrosted while minimizing energy consumption by the heater 140, thus preventing degradation of a detecting capability of the ice detecting sensor 120.
Further, if the ice storage container 180 is released or removed, the distance detected by the ice detecting sensor 220 would be detected to be farther than the distance detected when the ice storage container 180 is installed. Thus, whether or not the ice storage container 180 is detached may be also detected according to a change in the detected distance. If the ice storage container 180 is detected to have been released, discharging ice from the ice maker 100 is also stopped to prevent ice from pouring down onto the floor of the refrigerator or kitchen.
The plate heater 450 is made of a material that can generate heat when power or current is applied thereto, and has a plate form with a predefined prescribed) thickness. Alternatively, the plate heater may be a resistive element/heater or resistor. One end of the plate heater 450 may be electrically coupled to the PCB 425. The heat bridge 400 includes a connection plate or portion 403 coupled to the PCB 425 and a bent plate or portion 401 bent downwardly, namely, toward the transmitter 422 from the connection plate 403. The heat bridge 400 with such configuration transfers heat generated from the plate heater 450 to the transmitter 422.
The bent plate 401 includes a hole or an opening 402 allowing the transmitter 422 to pass therethrough. The diameter of the hole 422 is substantially the same as an outer diameter as that of the transmitter 422, so that when the transmitter 422 is inserted into the hole 402, an outer circumferential surface of the transmitter 422 and an inner circumferential surface of the hole 402 are substantially in contact or near contact with each other to allow transmission of heat to the transmitter 422 via the heat bridge 400 after being generated from the plate heater 450.
A thermal grease 460 may be provided between the plate heater 450 and the connection plate 403 of the heat bridge 400 if a gap exists therebetween to allow the plate heater 450 and the heat bridge 400 to be thermally coupled with each other. The thermal grease or dielectric should have relatively good thermal conductivity. Accordingly, the efficiency of transmission of heat to the heat bridge 400 via the thermal grease 460 after being generated from the plate heater 450 may be improved.
Because the plate heater 450 and the heat bridge 400 are provided, formation of frost can be prevented on the transmitter and/or receiver. In an alternative embodiment, the surface of the ice detecting sensor can be defrosted. The device prevents frost or moisture formation or defrosting operation can be simplified.
The two transmitters are disposed in a vertical direction relative to each other, e.g., in the direction of the ice storage container 180 at the ice maker 100, and
With reference to
The heat bridge 500 includes a connection plate or portion 503 coupled to the PCB 525 and a bent plate or portion 501 bent downwardly, namely, toward the transmitters 522a and 522b from the connection plate 503. The heat bridge 500 with such configuration allows transfer of heat generated from the plate heater 550 to the transmitters 522a and 522b.
The bent plate 501 includes holes or openings 502a and 502b allowing the transmitters 522a and 522b to pass therethrough. The diameters of the transmitters 522a and 522b are substantially the same as the diameters of the holes 502a and 502b. When the transmitters 522a and 522b are inserted into the holes 502a and 502b, outer circumferential surfaces of the transmitters 522a and 522b and inner circumferential surfaces of the holes 502a and 502b are in contact or near contact with each other.
A thermal grease or dielectric 560 is provided between the plate heater 550 and the connection plate 503 of the heat bridge 500, if to allow the plate heater 550 and the heat bridge 500 to be thermally coupled with each other. Accordingly, the efficiency of transmission of heat to the heat bridge 500 via the thermal grease 560 after being generated from the plate heater 550 can be improved. Because the plate heater 550 and the heat bridge 500 are provided, the formation of frost can be prevented. In an alternative embodiment, the surface of the ice detecting sensor can be defrosted and the device for performing defrosting can be simplified.
With reference to the
The bent plate 601 includes holes or openings 602a and 602b to allow the transmitters 622a and 622b to pass therethrough. Other than the horizontal arrangement, the description of
As shown in
With reference to
With reference to
With reference to
When the receivers 824a and 824b are provided in the horizontal direction, they can detect whether there is an error in detecting whether or not ice is completely full as well as an ice-full state upon detecting a signal transmitted from the transmitter. For example, if the receiver 824b has received a signal transmitted from the transmitter while the receiver 824a has not, an error regarding an ice-full state can be detected based on the signal received or detected by the receiver 824b. In
Any reference in this specification to “one embodiment,” “an embodiment,” “example embodiment,” etc., means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to effect such feature, structure, or characteristic in connection with other ones of the embodiments.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10-2008-0034854 | Apr 2008 | KR | national |
