REFRIGERATOR APPLIANCE AND ICE CLUMPING PREVENTION

FIELD OF THE DISCLOSURE

The present subject matter relates generally to refrigerator appliances or ice storage bins, such as in refrigerator appliances.

BACKGROUND OF THE DISCLOSURE

Refrigerator appliances generally include a cabinet that defines one or more chilled chambers for receipt of food articles for storage. Typically, one or more doors are rotatably hinged to the cabinet to permit selective access to food items stored in the chilled chamber. Further, refrigerator appliances commonly include ice making assemblies mounted within an icebox on one of the doors or in a freezer compartment. The ice is stored in an ice storage bin and is accessible from within the freezer chamber or may be discharged through a dispenser recess defined on a front of the refrigerator door.

A common issue for ice making assemblies and delivery systems is the clumping of ice within, for example, the ice storage bin. Often, ice will sublimate within the storage container. As touching ice pieces sublimate, they become bonded together. Once bonded, the dispensing assembly may be unable to dispense ice. A user may have to discard the entire clumped mass, which can be difficult and wasteful. The sublimation and bonding (i.e., clumping) of ice is especially likely if an extended period of time (e.g., several hours) passes between ice dispensing actions. Such extended periods of time often occur during normal use since typical users do not require ice at short, regular intervals.

Accordingly, a refrigerator appliance that utilizes systems and methods for preventing or mitigating ice clumping would be useful.

BRIEF DESCRIPTION OF THE DISCLOSURE

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In one exemplary aspect of the present disclosure, a method of operating an ice maker assembly for a refrigerator appliance is provided. The method may include a step of detecting an ice-usage event. The method may also include a step of detecting a potential ice clumping state following detecting the ice-usage event. The method may further include a step of initiating an ice agitator cycle in response to detecting the potential ice clumping event.

In another exemplary aspect of the present disclosure, a refrigerator appliance is provided. The refrigerator appliance may include a cabinet defining a freezer chamber. The refrigerator appliance may also include a freezer door attached to the cabinet. The freezer door may be movable between a closed position and an open position. In the closed position the freezer chamber may be enclosed by the freezer door. In the open position the freezer chamber may be accessible. The refrigerator appliance may further include an ice maker assembly including an ice storage bin, a feeler arm, an ice agitator, and a dispensing assembly. The refrigerator appliance may also include a controller operable for: detecting an ice-usage event; detecting a potential ice clumping state following detecting the ice-usage event; and initiating an ice agitator cycle in response to detecting the potential ice clumping event.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

FIG. 1 provides a perspective view of a refrigerator appliance according to one or more exemplary embodiments of the present subject matter.

FIG. 2 provides a perspective view of the exemplary refrigerator appliance of FIG. 1, with the doors of the fresh food chamber and freezer chamber shown in an open position.

FIG. 3 provides a diagrammatic illustration of a refrigerator appliance in communication with a remote computing device and with a remote user interface device according to one or more exemplary embodiments of the present subject matter.

FIG. 4 provides a side cross-sectional view of an icebox of the exemplary refrigerator appliance of FIG. 1 according to one or more exemplary embodiments of the present subject matter.

FIG. 5 provides a perspective view of an ice maker assembly positioned within the icebox of the exemplary refrigerator appliance of FIG. 1 according to one or more exemplary embodiments of the present subject matter.

FIG. 6 provides a perspective view of an ice storage bin assembly that may be incorporated into the exemplary refrigerator appliance of FIG. 1 according to one or more exemplary embodiments of the present subject matter.

FIG. 7 provides a flow diagram of an exemplary method of operating a refrigerator appliance according to one or more exemplary embodiments of the present subject matter.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings.

As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). The term “at least one of” in the context of, e.g., “at least one of A, B, and C” refers to only A, only B, only C, or any combination of A, B, and C. In addition, here and throughout the specification and claims, range limitations may be combined or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.

Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,” “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components or systems. For example, the approximating language may refer to being within a 10 percent margin, i.e., including values within ten percent greater or less than the stated value. In this regard, for example, when used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction, e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, e.g., clockwise or counterclockwise, with the vertical direction V.

The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” In addition, references to “an embodiment” or “one embodiment” does not necessarily refer to the same embodiment, although it may. Any implementation described herein as “exemplary” or “an embodiment” is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

FIG. 1 provides a perspective view of a refrigerator appliance 100 according to an exemplary embodiment of the present subject matter. Refrigerator appliance 100 includes a cabinet or housing 102 that extends between a top 104 and a bottom 106 along a vertical direction V, between a first side 108 and a second side 110 along a lateral direction L, and between a front side 112 and a rear side 114 along a transverse direction T. Each of the vertical direction V, lateral direction L, and transverse direction T are mutually perpendicular to one another.

Housing 102 defines chilled chambers for receipt of food items for storage. In particular, housing 102 defines fresh food chamber 122 positioned at or adjacent second side 110 of housing 102 and a freezer chamber 124 arranged at or adjacent first side 108 of housing 102. As such, refrigerator appliance 100 is generally referred to as a side-by-side refrigerator. It is recognized, however, that the benefits of the present disclosure apply to other types and styles of refrigerator appliances, e.g., a top mount refrigerator appliance, a bottom mount refrigerator appliance, or a single door refrigerator appliance. Consequently, the description set forth herein is for illustrative purposes only and is not intended to be limiting in any aspect to any particular refrigerator chamber configuration.

A refrigerator door 128 is rotatably hinged to an edge of housing 102 for selectively accessing fresh food chamber 122. In addition, a freezer door 130 is rotatably hinged to an edge of housing 102 for selectively accessing freezer chamber 124. Refrigerator door 128 and freezer door 130 are shown in the closed configuration in FIG. 1. One skilled in the art will appreciate that other chamber and door configurations are possible and within the scope of the present invention.

FIG. 2 provides a perspective view of refrigerator appliance 100 shown with refrigerator door 128 and freezer door 130 in the open position. As shown in FIG. 2, various storage components are mounted within fresh food chamber 122 to facilitate storage of food items therein as will be understood by those skilled in the art. In particular, the storage components may include bins 134 and shelves 136. Each of these storage components are configured for receipt of food items (e.g., beverages or solid food items) and may assist with organizing such food items. As illustrated, bins 134 may be mounted on refrigerator door 128 and freezer door 130 or may slide into a receiving space in fresh food chamber 122 or freezer chamber 124. It should be appreciated that the illustrated storage components are used only for the purpose of explanation and that other storage components may be used and may have different sizes, shapes, and configurations.

Referring now generally to FIG. 1, a dispensing assembly 140, and more particularly, an external part of the dispensing assembly 140, will be described according to exemplary embodiments of the present subject matter. Dispensing assembly 140 is generally configured for dispensing liquid water or ice. Although an exemplary dispensing assembly 140 is illustrated and described herein, it should be appreciated that variations and modifications may be made to dispensing assembly 140 while remaining within the present subject matter.

Dispensing assembly 140 and its various components may be positioned at least in part within a dispenser recess 142 defined on freezer door 130. In this regard, dispenser recess 142 is defined on a front side 112 of refrigerator appliance 100 such that a user may operate dispensing assembly 140 without opening freezer door 130. In addition, dispenser recess 142 is positioned at a predetermined elevation convenient for a user to access ice and enabling the user to access ice without the need to bend-over. In the exemplary embodiment, dispenser recess 142 is positioned at a level that approximates the chest level of a user.

In some embodiments, the dispensing assembly 140 includes an ice dispenser 144. The ice dispenser 144 may include a discharging outlet 146 for discharging ice pieces from dispensing assembly 140. An actuating mechanism 148, shown as a paddle, is mounted below discharging outlet 146 for operating ice or water dispenser 144. In alternative exemplary embodiments, any suitable actuating mechanism may be used to operate ice dispenser 144. For example, ice dispenser 144 can include a sensor (such as an ultrasonic sensor) or a button rather than the paddle. Discharging outlet 146 and actuating mechanism 148 are an external part of ice dispenser 144 and are mounted in dispenser recess 142.

As will be appreciated in more detail below, inside refrigerator appliance 100, an icebox 150 may be attached (e.g., directly, or indirectly) to the freezer door 130. The icebox 150 may define an ice making chamber 154 for housing an ice maker assembly 200, an ice storage bin assembly 152, and an internal part of the dispensing assembly 140.

A control panel 160 is provided for controlling the mode of operation. For example, control panel 160 includes one or more selector inputs 162, such as knobs, buttons, touchscreen interfaces, etc., such as a water dispensing button and an ice-dispensing button, for selecting a desired mode of operation such as crushed or non-crushed ice. In addition, selector inputs 162 may be used to specify a fill volume or method of operating dispensing assembly 140. In this regard, selector inputs 162 may be in communication with a processing device or controller 164. Signals generated in controller 164 operate refrigerator appliance 100 and dispensing assembly 140 in response to selector inputs 162. Additionally, a display 166, such as an indicator light or a screen, may be provided on control panel 160. Display 166 may be in communication with controller 164 and may display information in response to signals from controller 164.

As used herein, “processing device” or “controller” may refer to one or more microprocessors or semiconductor devices and is not restricted necessarily to a single element. The processing device can be programmed to operate refrigerator appliance 100 and dispensing assembly 140. The processing device may include, or be associated with, one or more memory elements (e.g., non-transitory storage media). In some such embodiments, the memory elements include electrically erasable, programmable read only memory (EEPROM). Generally, the memory elements can store information accessible processing device, including instructions that can be executed by processing device. Optionally, the instructions can be software or any set of instructions or data that when executed by the processing device, cause the processing device to perform operations.

Referring now to FIG. 3, a general schematic of a refrigerator appliance 300, such as but not limited to refrigerator appliance 100 described above, which communicates wirelessly with a remote user interface device 1001 and a network 1100 is provided. For example, as illustrated in FIG. 3, the refrigerator appliance 300 may include an antenna 90 by which the refrigerator appliance 300 communicates with, e.g., sends and receives signals to and from, the remote user interface device 1001 or network 1100. The antenna 90 may be part of, e.g., onboard, a communications module 92. The communications module 92 may be a wireless communications module operable to connect wirelessly, e.g., over the air, to one or more other devices via any suitable wireless communication protocol. For example, the communications module 92 may be a WI-FI® module, a BLUETOOTH® module, or a combination module providing both WI-FI® and BLUETOOTH® connectivity. The remote user interface device 1001 may be a laptop computer, smartphone, tablet, personal computer, wearable device, smart speaker, smart home system, or various other suitable devices. The communications module 92 may be onboard the controller 164 or may be a separate module.

The refrigerator appliance 300 may be in communication with the remote user interface device 1001 device through various possible communication connections and interfaces. The refrigerator appliance 300 and the remote user interface device 1001 may be matched in wireless communication, e.g., connected to the same wireless network. The refrigerator appliance 300 may communicate with the remote user interface device 1001 via short-range radio such as BLUETOOTH® or any other suitable wireless network having a layer protocol architecture. As used herein, “short-range” may include ranges less than about ten meters and up to about one hundred meters. For example, the wireless network may be adapted for short-wavelength ultra-high frequency (UHF) communications in a band between 2.4 GHz and 2.485 GHz (e.g., according to the IEEE 802.15.1 standard). In particular, BLUETOOTH® Low Energy, e.g., BLUETOOTH® Version 4.0 or higher, may advantageously provide short-range wireless communication between the refrigerator appliance 300 and the remote user interface device 1001. For example, BLUETOOTH® Low Energy may advantageously minimize the power consumed by the exemplary methods and devices described herein due to the low power networking protocol of BLUETOOTH® Low Energy.

The remote user interface device 1001 is “remote” at least in that it is spaced apart from and not structurally connected to the refrigerator appliance 300, e.g., the remote user interface device 1001 is a separate, stand-alone device from the refrigerator appliance 300 which communicates with the refrigerator appliance 300 wirelessly. Any suitable device separate from the refrigerator appliance 300 that is configured to provide or receive communications, information, data, or commands from a user may serve as the remote user interface device 1001, such as a smartphone (e.g., as illustrated in FIG. 3), smart watch, personal computer, smart home system, or other similar device. For example, the remote user interface device 1001 may be a smartphone operable to store and run applications, also known as “apps,” and some or all of the method steps disclosed herein may be performed by a smartphone app.

The remote user interface device 1001 may include a memory for storing and retrieving programming instructions. Thus, the remote user interface device 1001 may provide a remote user interface which may be an additional user interface to a user interface, e.g., control panel 160, of the refrigerator appliance 300. For example, the remote user interface device 1001 may be a smartphone operable to store and run applications, also known as “apps,” and the additional user interface may be provided as a smartphone app.

As mentioned above, the refrigerator appliance 300 may also be configured to communicate wirelessly with a network 1100. The network 1100 may be, e.g., a cloud-based data storage system including one or more remote computing devices such as remote databases or remote servers, which may be collectively referred to as “the cloud.” The network 1100 may include, e.g., one or more remote computing devices, such as a remote database, remote server, etc., in a distributed computing environment. Such distributed computing environments may include, for example, cloud computing, fog computing, or edge computing. For example, the refrigerator appliance 300 may communicate with the network 1100 over the Internet, which the refrigerator appliance 300 may access via WI-FI®, such as from a WI-FI® access point in a user's home, or in a commercial building.

The remote user interface device 1001 may be configured to capture or display images. For example, the remote user interface device 1001 may be a smartphone, e.g., as illustrated in FIG. 3, which includes both a camera (not shown) for capturing images and a display 1002, e.g., a touchscreen or other digital screen, for displaying images, as would be understood.

As noted above, controller 164 is capable of and may be operable to perform any methods, method steps, or portions of methods as disclosed herein. Additionally, such methods, methods steps or portions of methods may be performed locally (e.g., on controller 164) or remotely, e.g., by a remote computing device (e.g., in the “edge,” the “fog,” or in the “cloud,” as those of ordinary skill in the art will recognize as referring to a remote computing device, such as a server, database, or the like, in a distributed computing environment including at least one remote computing device in communication with the local controller 164, such as the exemplary network 1100 illustrated in FIG. 3 and described above). Also by way of example, such performance may be mixed, such as partially local and partially remote.

Referring now generally to FIGS. 4 through 6, the ice maker assembly 200, the ice storage bin assembly 152, and an internal part of the dispensing assembly 140 will be described according to exemplary embodiments of the present subject matter. As illustrated in FIGS. 4 and 5, the ice maker assembly 200 is mounted in the icebox 150 within the ice making chamber 154. In some embodiments, the ice maker assembly 200 receives a flow of water from a water supply spout 202. The water supply spout 202 may be configured to discharge a flow of water into a mold body 204 of an ice tray 206. During use, the water may freeze within the mold body 204 and form ice pieces which may be stored in ice storage bin assembly 152. For instance, the mold body 204 may include one or more compartments for receiving the flow of water discharged from the water supply spout 202, and retaining the water until ice pieces are formed (or at least a portion of the liquid water may be retained).

In some embodiments, e.g., as illustrated in FIGS. 4 and 5, the ice maker assembly 200 may be a twist tray ice maker assembly. In such embodiments, the ice maker assembly 200 may include a mount unit 208. The mount unit 208 may be positioned in the icebox 150 and mounted to one or more internal surfaces of the icebox 150. The mount unit 208 may be coupled to the ice tray 206, e.g., the mount unit 208 may be configured to releasably receive the ice tray 206. The ice tray 206 may comprise a flexible, e.g., twistable, material, such as the ice tray 206 may comprise a plastic material which is sufficiently flexible to twist the ice tray 206 in order to promote disengagement, e.g., release, of ice pieces in the ice tray 206, as is understood by those of ordinary skill in the art.

In some embodiments, the mount unit 208 may include a first mount unit 209 and a second mount unit 211. The first mount unit 209 and the second mount unit 211 may be spaced apart from one another along a central axis 210 of the ice maker assembly 200, such as a central axis 210 of the ice tray 206 of the ice maker assembly 200. In various embodiments, a direction of the central axis 210 corresponds to, e.g., is along or parallel to, a longitudinal axis of the ice tray 206 when the ice tray 206 is installed to the mount unit 208.

In various embodiments, the mount unit 208 includes a rotor 212 configured to rotate relative to the central axis 210. The first mount unit 209 may be fixed to a wall of the refrigerator appliance 100, such as a wall of the icebox 150 in embodiments where the refrigerator appliance 100 includes an icebox 150. The first mount unit 209 may include a motor or other actuation device 214 operably coupled to the rotor 212 to rotate relative to the central axis 210, e.g., about the central axis 210. When the ice tray 206 is installed onto the rotor 212, rotation of the rotor 212 such as by the actuation device 214, causes the ice tray 206 to dump or deposit ice or other contents from the ice tray 206.

In some embodiments, the ice maker assembly 200 may include a dedicated controller 216, e.g., similar to the controller 164 of the refrigerator appliance 100 which is described above. In embodiments where the ice maker assembly 200 is incorporated into a refrigerator appliance such as the exemplary refrigerator appliance 100 described hereinabove, the dedicated controller 216 may be in addition to the controller 164 of the refrigerator appliance 100 and may be in communication with the controller 164, and the controller 216 of the ice maker assembly 200 may be in operative communication with other components of the ice maker assembly 200 and may be configured specifically for controlling or directing operation of such components, e.g., the actuation device 214.

When harvesting ice pieces, for example, the controller 216 may cause the actuation device 214 to rotate a first amount, e.g., through a first number of degrees about the central axis 210, to twist the ice tray 206 and thereby promote release of ice pieces from the compartments of the mold body 204, such as rotating the first amount in a first direction followed by rotating the same amount, e.g., the first amount, in a second direction opposite the first direction to twist the ice tray 206 to release ice pieces from the compartments of the mold body 204. After rotating the first amount, e.g., after twisting the ice tray 206, the controller 216 may then cause the actuation device 214 to rotate a second amount, e.g., through a second number of degrees about the central axis 210, greater than the first amount to tip over or invert the ice tray 206, allowing the ice pieces to fall, e.g., by gravity, from the ice tray 206 into the ice storage bin assembly 152 positioned there below.

Additionally, in some embodiments, the ice maker assembly 200 may include a feeler arm 260 that may be utilized to detect or sense when an ice storage level of the ice storage bin assembly 152 has changed. Particularly, the feeler arm 260 may be utilized to detect or sense when the ice storage bin assembly 152 has reached a maximum storage capacity. The feeler arm 260 may be articulable about a feeler axis 262 between an original position (see, e.g., FIG. 5) and an upward position. In the upward position, the feeler arm 260 may be articulated upward about the feeler axis 262 approximately along the vertical direction V. Further, when the feeler arm 260 is articulated to the upward position, it may be detected or determined that the ice storage bin assembly 152 has reached its maximum ice storage capacity. For instance, the feeler arm 260 may be positioned within the ice storage bin assembly 152 at a predetermined vertical height that may correspond to the maximum storage capacity of the ice storage bin assembly 152 (see, e.g., FIG. 4).

When ice pieces interact with the bottom of the feeler arm 260, the feeler arm 260 may be actuated toward the upward position. In this regard, it may be detected that the ice storage bin assembly 152 is at the maximum ice storage capacity. In some embodiments, when the maximum ice storage capacity of the ice storage bin assembly 152 is reached, operation of the ice maker assembly 200 may be halted, e.g., the ice maker assembly 200 may be turned off. Further, when the feeler arm 260 is actuated from the upward position back to the original position, it may be detected or determined that the ice storage bin assembly 152 is no longer at the maximum ice storage capacity. In some embodiments, when the feeler arm 260 is actuated from the upward position back to the original position, operation of the ice maker assembly 200 may be resumed, e.g., the ice maker assembly 200 may be turned on.

Turning now particularly to FIGS. 4 and 6, exemplary embodiments of the ice storage bin assembly 152 are provided. In some embodiments, the ice storage bin assembly 152 includes bin body 218. The bin body 218 may be extended along the vertical direction V from a bottom end 220 to a top end 222. The bin body 218 may generally be formed as a solid, nonpermeable structure having one or more sidewalls 224. The bin body 218 may define a storage volume 226 to receive ice pieces therein (e.g., ice pieces harvested from ice maker assembly 200). In some embodiments, one portion of bin body 218 (e.g., sidewalls 224) may be formed from a transparent material, such as a suitable rigid polymer (e.g., acrylic, polycarbonate, etc.), through which a user may view the contents of storage volume 226. In some embodiments, at top end 222, bin body 218 defines a bin opening 228 through which ice pieces may pass into storage volume 226. Below top end 222 (e.g., within ice storage bin assembly 152, such as proximate to the bottom end 220), bin body 218 may define a dispenser opening 230 through which ice pieces may pass from storage volume 226 to an ice chute 141. In some embodiments, the ice chute 141 is an internal part of dispensing assembly 140 that directs or routes ice pieces from the storage volume 226 to the discharging outlet 146. In some embodiments, the entirety of top end 222 is open and unobstructed. In other words, the top end 222 and bin opening 228 may be free of any lid or enclosing portion.

Additionally, in some embodiments (e.g., FIG. 4), a gear assembly 232 is provided. In some embodiments, the gear assembly 232 may be attached (e.g., directly or indirectly) to the bin body 218. An ice sweep 234 positioned within bin body 218 may be in mechanical communication with gear assembly 232 to rotate about a predetermined axis (e.g., a sweep axis 236 or parallel to the transverse direction T). In certain embodiments, an ice cover 238 is positioned, at least in part, between ice sweep 234 and storage volume 226 along the transverse direction T. The ice cover 238 may at least partially cover ice sweep 234 and provide support to ice pieces within storage volume 226. Ice cover 238 may thus at least partially define a portion of storage volume 226. In some such embodiments, ice cover 238 defines a cover opening 240 that generally extends along the transverse direction T between storage volume 226 and ice sweep 234. In certain embodiments, cover opening 240 is perpendicular to dispenser opening 230.

In some embodiments, an ice agitator 242 is positioned within storage volume 226. For instance, ice agitator 242 may extend, at least in part, along the transverse direction T through or from ice cover 238 to a location within storage volume 226 (e.g., below bin opening 228). In some such embodiments, ice agitator 242 includes, or is provided as, a single, continuous, folded wire. The wire of ice agitator 242 may extend as an integral (e.g., unitary and monolithic) structure from a first end 244 (e.g., connecting the gear assembly 232) to a second end 246 (e.g., connected directly or indirectly to the bin body 218). In certain embodiments, ice agitator 242 is fixed to ice sweep 234. Both ice agitator 242 and ice sweep 234 may thus rotate in tandem about sweep axis 236. Optionally, one or more sealing structures (e.g., mated gasket-channel about sweep axis 236) may be formed on ice sweep 234 or ice agitator 242 to prevent water from flowing to gear assembly 232.

Additionally, in some embodiments, the ice storage bin assembly 152 may include an ice piece crushing assembly 250 that may be attached (e.g., directly or indirectly) to the ice sweep 234. The ice piece crushing assembly 250 may include a plurality of blades 252 that are configured to crush or cut ice pieces prior to the ice pieces being motivated toward the dispenser opening 230. During use, the ice piece crushing assembly 250 may selectively utilize the plurality of blades 252 to selectively crush ice pieces (e.g., to form crushed ice pieces).

During use, the ice maker assembly 200 may form and harvest ice pieces. The ice pieces that are harvested from the ice maker assembly 200 may be stored within the ice storage bin assembly 152. In some embodiments, ice pieces may continuously be formed and harvested from the ice maker assembly 200 until a maximum ice storage capacity of the ice storage bin assembly 152 is reached. As described above, in some embodiments, the maximum ice storage capacity of the ice storage bin is reached when a feeler arm 260 is actuated upward by the ice pieces stored within the ice storage bin assembly 152.

In some instances, ice pieces may be stored within the ice storage bin assembly 152 for an extended period of time without any ice pieces being removed or dispensed from the ice storage bin assembly 152. For example, the ice storage bin assembly 152 may be at its maximum ice storage capacity for an extended period of time without any discharging or removing of ice pieces from the ice storage bin assembly 152. This lack of usage of ice pieces for an extended period of time may generally be referred to as a “low ice usage state” of the ice storage bin assembly 152. In some embodiments, the low ice usage state of the ice storage bin assembly 152 may be based on a time since one or more ice usage events have been detected. Ice usage events may include events or operations that may indicate ice pieces have been discharged or removed from the storage volume 226 of the ice storage bin assembly 152.

For example, an ice usage event may include the actuation (e.g., downward actuation, such as from the upward position back to the original position) of the feeler arm 260. This may indicate that the amount of ice pieces within the ice storage bin assembly 152 has decreased as the ice storage bin assembly 152 is no longer at maximum ice storage capacity. As another example, an ice usage event may include the opening of the freezer door 130. This may indicate that ice pieces may have been removed e.g., manually by a user, from the ice storage bin assembly 152. As yet another example, an ice usage event may be or include the discharging of ice pieces from the ice storage bin assembly 152, e.g., via the dispensing assembly 140. It should be appreciated that the low ice usage state of the ice storage bin assembly 152 may be based on one or more of the ice usage events being detected.

Often, when the ice storage bin assembly 152 is in a low ice usage state for an extended period of time, the likelihood of ice piece clumping (e.g., ice pieces freezing together) may be increased. Clumping of ice pieces may present numerous difficulties with regards to the dispensing and collection of ice pieces. Accordingly, embodiments of the present subject matter provide systems and methods for proactively agitating ice pieces stored within the ice storage bin assembly 152. In this regard, embodiments of the present subject matter may advantageously mitigate or prevent the clumping of ice pieces.

For example, referring now to FIG. 7, embodiments of the present subject matter may include one or more methods for operating an ice maker assembly of a refrigerator appliance, such as the exemplary refrigerator appliance 100 described above, as well as other possible exemplary refrigerator appliances. The exemplary methods according to the present subject matter may include a method 400, for example, as illustrated in FIG. 7. A controller of the refrigerator appliance, such as the controller 164 of the exemplary refrigerator appliance 100, may be programmed to implement method 400, for example, the controller, such as controller 164, may be capable of and may be operable to perform any methods and associated method steps as disclosed herein.

In some embodiments, the method includes a step 410 of detecting an ice-usage event. Ice-usage events may be events or operations that correspond to the removal (e.g., physical removal or removal via a dispensing assembly) of ice pieces from an ice storage bin, e.g., ice storage bin assembly 152, of the refrigerator appliance. For example, step 410 of detecting an ice-usage event may include sensing ice pieces within an ice storage bin at a feeler arm, e.g., the feeler arm 260, disposed above at least a portion of the ice storage bin. As described in more detail above, the feeler arm, e.g., the feeler arm 260, may be utilized to sense when an ice storage level of the ice storage bin has changed. In this regard, when the feeler arm 260 senses a change in the ice storage level of the ice storage bin (e.g., in response to receiving a signal corresponding to engagement between the feeler arm and a volume of ice), an ice-usage event may be detected.

As another example, the step 410 of detecting an ice-usage event may include sensing that a freezer door, e.g., the freezer door 130, of the refrigerator appliance is in an open position. For instance, the sensing of the freezer door in the open position may be determined based on a signal received from any suitable sensor (e.g., a reed switch) directed at or in selective engagement with the freezer door (e.g., as may be generally understood). In some instances, when the freezer door is in the open position, ice pieces may be physically removed, e.g., by a user, from the ice storage bin. In this regard, when the freezer door is in the open position, an ice-usage event may be detected.

As yet another example, the step 410 of detecting an ice-usage event may include dispensing ice pieces from an ice storage bin via a dispensing assembly, e.g., the dispensing assembly 140. For instance, the dispensing of ice pieces from the ice storage bin may be determined based on a first signal received in response to manipulation of an ice-dispensing button (e.g., manipulation of a selector input, such as selector input 162, for selecting a desired operation mode such as crushed or non-crushed). In such instances, when a user selects a crushed or non-crushed ice operation, an ice-usage event may be detected.

Further, in some other instances, the dispensing of ice pieces from the ice storage bin may be determined based on the first signal being received and a second signal received in response to the actuation of an actuating mechanism (e.g., actuating mechanism 148). In this regard, when a user selects a crushed or non-crushed ice operation mode and actuates the actuating mechanism to dispense ice pieces in the crushed or non-crushed operation mode, an ice-usage event may be detected. In other words, when ice pieces have been dispensed or discharged from the ice storage bin, e.g., through the dispensing assembly, the step 410 may detect the ice-usage event.

In some embodiments, the method 400 may include a step 420 of detecting a potential ice clumping state of the ice maker assembly following the step 410 of detecting the ice-usage event. Generally, the potential ice clumping state of the ice maker assembly may indicate a state within the ice maker assembly, or more particularly, in the ice storage bin, in which sublimation or refreezing of ice pieces is likely.

In some instances, the potential ice clumping state may include a time from the detection of the ice-usage event, e.g., as detected at step 410. In other words, the method 400 may include determining a predetermined timespan (e.g., in seconds, minutes, or hours) has expired since the last ice-usage event was detected. Optionally, each ice-usage event may prompt a timer configured to measure the predetermined timespan and, for instance, transmit or generate a signal indicating the moment at which the predetermined timespan expires. If a new ice-usage event occurs before expiration of the predetermined timespan, the timer may be restarted. As described in more detail above, an ice-usage event may generally correspond to actuation of the feeler arm, opening of the freezer door, dispensing of ice pieces from the ice storage bin, or a combination thereof.

In additional or alternative embodiments, a water sensor (e.g., conductivity sensor or any other suitable sensor configured to detect melted liquid water) may be mounted within the ice maker assembly in operative communication with the controller. For instance, the water sensor may be mounted on or within a bottom portion of the ice storage bin. Optionally, a recess may be formed in which a predetermined volume of liquid water may collect. In response to collection of the predetermined volume of liquid water, water sensor may transmit a corresponding signal (e.g., to the controller).

Further, in additional or alternative embodiments, a temperature sensor (e.g., thermistor, thermocouple, or any other suitable sensor configured to detect temperature) may be mounted within ice maker assembly in operative (e.g., electrical or wireless) communication with the controller. For instance, temperature sensor may be mounted on or adjacent to the ice storage bin. Based on a temperature detected temperature sensor may transmit a corresponding signal (e.g., to the controller).

In such additional or alternative embodiments, the potential ice clumping state includes receiving a sensor signal (e.g., transmitted from the water sensor or the temperature sensor, as described above). As an example, a signal may be received by the controller in response to a predetermined volume of water being detected within the dispensing assembly, such as in the ice storage bin. As an additional or alternative example, a signal may be received by the controller in response to a predetermined temperature (e.g., maximum temperature limit) being detected at the ice maker assembly, such as within a storage volume thereof. Based on one or more received sensor signals, the controller may determine sublimation is possible or likely.

In some embodiments, the method 400 includes a step 430 of initiating an ice agitator cycle in response to detecting the potential ice clumping event. The step 430 may include driving a motor (e.g., gear assembly 232) to rotate an ice agitator, e.g., ice agitator 242, positioned within an ice storage bin periodically. In some embodiments, a controller, such as the controller 164, may direct the motor (e.g., gear assembly 232) that is mechanically coupled to the ice agitator to rotate the ice agitator periodically. The controller may utilize any suitable programmed pattern, predetermined schedule, conditional formula, etc., to direct the motor to rotate the ice agitator periodically.

Notably, rotation of the ice agitator may be utilized to prevent or mitigate ice clumping that may occur when the ice storage bin is in the potential ice clumping state. In some embodiments, directing the motor to rotate the ice agitator positioned within the ice storage bin periodically includes driving the motor to rotate the ice agitator positioned within the ice storage bin periodically in a clockwise and anticlockwise motion. Specifically, driving the motor to rotate the ice agitator in a clockwise and anticlockwise motion may include driving the motor to rotate the ice agitator in a first direction for a first predetermined amount, e.g., a first number of degrees or a first amount of time, followed by driving the motor to rotate the ice agitator in a second direction for a second predetermined amount, e.g., a second number of degrees or a second amount of time. The second direction may be opposite the first direction.

Additionally or alternatively, the method 400 may include a step of providing a user notification in response to the ice agitator cycle being initiated. The user notification may notify a user of the refrigerator appliance that the ice agitator cycle has been initiated to mitigate or prevent ice clumping within the ice storage bin. In some such exemplary embodiments, the step of providing a user notification in response to the ice agitator cycle being initiated includes providing a user notification on a remote user interface device, e.g., remote user interface device 1001, in response to the ice agitator cycle being initiated. Additionally or alternatively, in some other exemplary embodiments, the step of providing a user notification in response to the ice agitator cycle being initiated includes providing a user notification on a display, e.g., display 166, of the refrigerator appliance in response to the ice agitator cycle being initiated.

In some embodiments, the method 400 may include a step 440 of halting the ice agitator cycle. For instance, after the ice agitator cycle has been initiated, e.g., to mitigate or prevent ice clumping, if an operation indicative of a change in the ice level is detected, the ice agitator cycle will be halted.

In some embodiments, the ice agitator cycle may be halted in response to one or more conditions being met. For example, the ice agitator cycle may be halted in response to an in-cycle ice-usage event being detected. The step 440 may include monitoring for an in-cycle ice usage event. The in-cycle ice usage event may be an ice usage event (e.g., as described in more detail above) that is detected during the ice agitator cycle. For instance, the in-cycle ice usage event may correspond to the actuation of the feeler arm, the opening of the freezer door, and the dispensing of ice pieces from dispensing assembly. As another example, the ice agitator cycle may be halted in response to a time out condition being met. That is the ice agitator cycle may be halted after predetermined cycle time has been met or exceeded.

Embodiments of the present subject matter advantageously provide a refrigerator appliance that includes features to mitigate or prevent ice pieces from clumping together within a storage volume of an ice storage bin at a freezer door. Specifically, the refrigerator appliance may be configured to detect a low ice usage state of the ice storage bin based on the operation, or lack thereof, of one or more components of the refrigerator appliance. Specifically, operation, or lack thereof, of the freezer door, a feeler arm, or a dispensing assembly of the refrigerator may be monitored. In response, to the operation, or lack thereof, of one or more of these components being detected, an ice agitator cycle may advantageously be initiated. The ice agitator cycle may agitate or shake ice pieces within the ice storage bin to proactively mitigate or prevent ice pieces from clumping. The ice agitator cycle may advantageously be continued until one or more ice usage events of the ice maker appliance are detected.

Additionally, embodiments of the present subject matter may advantageously provide a notification to a user of the refrigerator appliance in response to the ice agitator cycle being initiated. In some instances, this notification to a user may be provided through a remote user interface device, (e.g., a smartphone). Additionally or alternatively, the notification to the user may be provided directly on the refrigerator appliance (e.g., on a display of the refrigerator appliance).

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

REFRIGERATOR APPLIANCE AND ICE CLUMPING PREVENTION

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