SYSTEMS FOR ICE MOLD ASSEMBLIES IN ICE MAKER APPLIANCES

FIELD OF THE INVENTION

The present subject matter relates generally to ice makers for refrigerator appliances.

BACKGROUND OF THE INVENTION

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 a 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.

Conventional ice making assemblies can be large, inefficient, experience a variety of performance related issues, and only produce one shape or size of ice cube. For example, conventional twist tray icemakers include a partitioned plastic mold that is physically deformed to break the bond formed between ice and the tray. However, these icemakers require additional room to fully rotate and twist the tray. In addition, the ice cubes are frequently fractured during the twisting process. When this occurs, a portion of the cubes may remain in the tray, thus resulting in overfilling during the next fill process. Further, conventional ice making assemblies only offer one style of ice cube.

BRIEF DESCRIPTION OF THE INVENTION

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

In one example embodiment, a mold assembly is removably mounted to an ice making assembly. The mold assembly includes a frame configured for receipt within a receiving chamber of the ice making assembly, a mold support, and a flexible mold. The flexible mold is positioned proximate the mold support and defines a mold cavity which is configured to receive a liquid. The mold support includes a plurality of holes configured for directing airflow through the mold support and around a bottom of the flexible mold.

In another example embodiment, a mold assembly is removably mounted to an ice making assembly. The mold assembly includes a frame that is configured for receipt within a receiving chamber of the ice making assembly. The mold assembly also includes a mold support that includes a plurality of holes, and a flexible mold that is proximate the mold support and defines a mold cavity configured to receive a liquid. The mold assembly also includes at least one lifter that is configured to contact and deform the flexible mold. The plurality of holes of the mold support are configured for directing airflow through the mold support and around a bottom of the flexible mold.

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 an example embodiment of the present subject matter.

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

FIG. 3 provides a perspective view of an icebox and ice making assembly for use with the example refrigerator appliance of FIG. 1 according to an example embodiment of the present subject matter.

FIG. 4 provides a detailed perspective view of the icebox and ice making assembly of FIG. 3 according to an example embodiment of the present subject matter.

FIG. 5 provides a rear perspective view of a mold assembly cartridge according to an example embodiment of the present subject matter.

FIG. 6 provides a bottom, rear perspective view of the mold assembly cartridge of FIG. 5.

FIG. 7 provides a top perspective view of the mold assembly cartridge of FIG. 5.

FIG. 8 provides a side, section view of the mold assembly cartridge of FIG. 5.

FIG. 9 provides a perspective view of the example ice making assembly of with the mold assembly of FIG. 5 installed.

FIG. 10 provides a perspective view of the example ice making assembly of with the mold assembly of FIG. 5 removed.

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 OF THE INVENTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. 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 example embodiment of the present subject matter. Refrigerator appliance 100 includes a cabinet 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.

Cabinet 102 defines chilled chambers for receipt of food items for storage. In particular, cabinet 102 defines fresh food chamber 122 positioned at or adjacent top 104 of cabinet 102 and a freezer chamber 124 arranged at or adjacent bottom 106 of cabinet 102. As such, refrigerator appliance 100 is generally referred to as a bottom mount refrigerator. It is recognized, however, that the benefits of the present disclosure apply to other types and styles of refrigerator appliances such as, e.g., a top mount refrigerator appliance, a side-by-side style 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.

Refrigerator doors 128 are rotatably hinged to an edge of cabinet 102 for selectively accessing fresh food chamber 122. In addition, a freezer door 130 is arranged below refrigerator doors 128 for selectively accessing freezer chamber 124. Freezer door 130 is coupled to a freezer drawer (not shown) slidably mounted within freezer chamber 124. Refrigerator doors 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 doors 128 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 and/or solid food items) and may assist with organizing such food items. As illustrated, bins 134 may be mounted on refrigerator doors 128 or may slide into a receiving space in fresh food chamber 122. 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 will be described according to example embodiments of the present subject matter. Dispensing assembly 140 is generally configured for dispensing liquid water and/or ice. Although an example 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 one of refrigerator doors 128. 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 refrigerator door 128. 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 example embodiment, dispenser recess 142 is positioned at a level that approximates the chest level of a user.

Dispensing assembly 140 includes an ice dispenser 144 including a discharging outlet 146 for discharging ice 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 example 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.

By contrast, inside refrigerator appliance 100, refrigerator door 128 may define an icebox 150 (FIGS. 2 and 3) housing an icemaker and an ice storage bin 152 that are configured to supply ice to dispenser recess 142. In this regard, for example, icebox 150 may define an ice making chamber 154 for housing an ice making assembly, a storage mechanism, and a dispensing mechanism.

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, inputs 162 may be used to specify a fill volume or method of operating dispensing assembly 140. In this regard, 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 and/or data that when executed by the processing device, cause the processing device to perform operations.

Referring now generally to FIGS. 3 through 10, an ice making assembly 200 that may be used with refrigerator appliance 100 will be described according to example embodiments of the present subject matter. As illustrated, ice making assembly 200 is mounted on icebox 150 within ice making chamber 154 and is configured for receiving a flow of water from a water supply spout 202 (see, e.g., FIG. 3). In this manner, ice making assembly 200 is generally configured for freezing the water to form ice cubes 204 (FIG. 8) which may be stored in storage bin 152 and dispensed through discharging outlet 146 by dispensing assembly 140. However, it should be appreciated that ice making assembly 200 is described herein only for the purpose of explaining aspects of the present subject matter. Variations and modifications may be made to ice making assembly 200 while remaining within the scope of the present subject matter. For example, ice making assembly 200 could instead be positioned within freezer chamber 124 of refrigerator appliance 100 and may have any other suitable configuration.

According to the illustrated embodiment, ice making assembly 200 includes a resilient mold 210 (FIG. 4) that defines a mold cavity 212 (FIG. 4). In general, resilient mold 210 is positioned below water supply spout 202 for receiving the gravity-assisted flow of water from water supply spout 202. Resilient mold 210 may be constructed from any suitably resilient material that may be deformed to release ice cubes 204 after formation. For example, according to the illustrated embodiment, resilient mold 210 is formed from silicone or another suitable hydrophobic, food-grade, and resilient material.

According to the illustrated embodiment, resilient mold 210 defines five (5) mold cavities 212, each being shaped and oriented for forming a separate ice cube 204. In this regard, for example, water supply spout 202 is configured for refilling resilient mold 210 to a level above a divider wall (not shown) within resilient mold 210 such that the water overflows into mold cavities 212 evenly. According to still other embodiments, water supply spout 202 could have a dedicated discharge nozzle positioned over each mold cavity 212. Furthermore, it should be appreciated that according to alternative embodiments, ice making assembly 200 may be scaled to form any suitable number of ice cubes 204, e.g., by decreasing or increasing the number of mold cavities 212 defined by resilient mold 210.

Ice making assembly 200 may further include a mold support 220 which is configured to hold resilient mold 210 within ice making assembly 200 for freezing the water within mold cavities 212 to form one or more ice cubes 204. Mold support 220 may be configured to hold resilient mold 210 without directly contacting a bottom 214 of resilient mold 210. In general, mold support 220 may be formed from any suitable plastic material and may be positioned at least two millimeters (2 mm) apart from resilient mold 210. Specifically, according to the illustrated embodiment, mold support 220 is formed from plastic and is positioned about two millimeters (2 mm) below bottom 214 of resilient mold 210. It should be appreciated that as used herein, terms of approximation, such as “approximately,” “substantially,” or “about,” refer to being within a ten percent margin of error.

In addition, mold support 220 may include an inlet air cavity 224 that is fluidly coupled with a cool air supply (e.g., illustrated as a flow of cooling air 226). Generally, inlet air duct 224 generally receives the flow of cooling air 226 from a sealed system of refrigerator appliance 100 and directs it through mold support 220 to cool resilient mold 210. According to the illustrated embodiment, inlet air cavity 224 provides the flow of cooling air 226 from a rear end 228 of ice making assembly 200 (e.g., to the left along the lateral direction L as shown in FIG. 4) through mold support 220 towards a front end 230 of ice making assembly 200 (e.g., to the right along the lateral direction L as shown in FIG. 4, i.e., the side where ice cubes 204 are discharged into storage bin 152).

Specifically, as seen in FIGS. 6 through 8, mold support 220 may include a plurality of holes 500. Inlet air duct 224 may receive the flow of cooling air 226 and the plurality of holes 500 may permit cooling air 226 to flow through mold support 220 in order to cool resilient mold 210. As such, cooling air 226 cools resilient mold 210 via convection heat transfer. Mold support 220 may further include a front wall 502 (FIG. 8) in order to direct the flow of cooling air 226 through the plurality of holes 500. In order to permit the flow of cooling air 226 underneath and around the resilient mold 210, bottom 214 of resilient mold 210 may be at least two millimeters (2 mm) above, in the vertical direction V, the plurality of holes 500 of mold support 220. For example, bottom 214 of resilient mold 210 is separate from mold support 220 which permits an open space for the flow of cooling air 226 to flow around resilient mold 210. In the illustrated embodiment of FIG. 7, the plurality of holes 500 includes about fourteen (14) holes per cavity 212, however in other example embodiments the plurality of holes 500 may include about two (2) holes per cavity 212.

As shown in FIG. 8, ice making assembly 200 may further include a lifter mechanism 240 that is positioned below resilient mold 210 and is generally configured for facilitating the ejection of ice cubes 204 from mold cavities 212. In this regard, lifter mechanism 240 is movable between a lowered position (e.g., as shown in FIG. 8) and a raised position (not shown). Specifically, lifter mechanism 240 includes a lifter arm 242 that extends substantially along the vertical direction V and passes through a lifter channel 244 defined within mold support 220. In this manner, lifter channel 244 may guide lifter mechanism 240 as the lifter mechanism 240 slides along the vertical direction V.

In addition, lifter mechanism 240 include a lifter projection 246 that extends from a top of lifter arm 242 along the lateral direction L. As illustrated, lifter projection 246 is generally positioned flush within mold support 220. In this manner, in the down position, mold support 220 and lifter projection 246 may not contact/interfere with resilient mold 210 permitting a smooth bottom surface of ice cubes 204.

Referring now specifically to FIG. 5, mold support 220 may further define a hole for receiving a temperature sensor 250 which is used to determine when ice cubes 204 (FIG. 8) have been formed such that an ejection process may be performed. In this regard, for example, temperature sensor 250 may be in operative communication with controller 164 which may monitor the temperature within mold support 220 and the time water has been in mold cavities 212 to predict when ice cubes 204 have been fully frozen. As used herein, “temperature sensor” may refer to any suitable type of temperature sensor. For example, the temperature sensors may be thermocouples, thermistors, or resistance temperature detectors. In addition, although example positioning of a single temperature sensor 250 is illustrated herein, it should be appreciated that ice making assembly 200 may include any other suitable number, type, and position of temperature sensors according to alternative embodiments.

Referring again generally to FIG. 4, ice making assembly 200 may include a drive mechanism 276 which is operably coupled to lifter mechanism 240 to selectively raise lifter mechanism 240 to discharge ice cubes 204 during operation. Specifically, according to the illustrated embodiment, drive mechanism 276 includes a drive motor (not shown). As used herein, “motor” may refer to any suitable drive motor and/or transmission assembly for rotating a system component. For example, the motor may be a brushless DC electric motor, a stepper motor, or any other suitable type or configuration of motor. Alternatively, for example, the motor may be an AC motor, an induction motor, a permanent magnet synchronous motor, or any other suitable type of AC motor. In addition, the motor may include any suitable transmission assemblies, clutch mechanisms, or other components. The motor may be mechanically coupled to a rotating cam 280. Lifter mechanism 240, or more specifically lifter arm 242, may ride against rotating cam 280 such that the profile of rotating cam 280 causes lifter mechanism 240 move between the lowered position and the raised position as the motor rotates rotating cam 280. In addition, according to an example embodiment, lifter mechanism 240 may include a roller 282 mounted to the lower end of lifter arm 242 for providing a low friction interface between lifter mechanism 240 and rotating cam 280.

More specifically, as shown in FIGS. 5 through 6, ice making assembly 200 may include a plurality of lifter mechanisms 240, each of the lifter mechanisms 240 being positioned below one of the ice cubes 204 within resilient mold 210 or being configured to raise a separate portion of resilient mold 210. In such an embodiment, rotating cams 280 are mounted beneath rollers 282 on a roller axle 284. As the motor rotates cams 280, cams 280 may simultaneously move lifter arms 242 along the vertical direction V. In this manner, each of the plurality of rotating cams 280 may be configured for driving a respective one lifter mechanism 240. In addition, as illustrated in FIG. 6, roller axle 284 may extend between rollers 282 of adjacent lifter mechanisms 240 to maintain a proper distance between adjacent rollers 282 and to keep them engaged on top of rotating cams 280.

Referring to FIGS. 5 through 8, the removable mold assembly 400 may be generally rectangular in shape. The removable mold assembly 400 may include a frame 410, mold support 220, the resilient or flexible mold 210, and the lifter mechanism 240 including lifter arm 242, lifter projection 246, and roller axle 284. The frame 410 may include a mold frame 450. The mold frame 450 may support the mold support 220. In one example, the mold support 220 is located within frame 410.

With reference to FIG. 8, the flexible mold 210 may include a mold bottom 214 and a mold side 216. The mold side 216 may extend in the vertical direction V from the mold bottom 214. In one embodiment, the mold side 216 is cylindrical. In another embodiment, the mold side 216 includes a plurality of mold sides 216 that form a closed cross-section in the lateral direction L and transverse direction T. In one example, the plurality of mold sides 216 includes four mold sides 216 forming a square cross-section. As such, the mold bottom 214 and the mold side 216 may form the mold cavity 212. Further, any suitable number of mold sides 216 may be used to form various shapes of the mold cavity 212.

The mold bottom 214 may include a stress relief feature 218. The stress relief feature 218 may be formed at or near a center of the mold bottom 214. In one example, the stress relief feature 218 is an inverted cup formed into the mold bottom 214. In other words, a center portion of the mold bottom 214 may be raised in the vertical direction V with respect to the surrounding portion of the mold bottom 214. The stress relief feature 218 may resemble a dome shape at or near the center of the mold bottom 214. However, it should be appreciated that the stress relief feature 218 may have any suitable shape such that the center portion of the mold bottom 214 is raised in the vertical direction V with respect to the surrounding portion of the mold bottom 214.

Lifter projection 246 may be planar with respect to the lateral direction L and the transverse direction T. In other words, a plane of the top surface of the lifter projection 246 may be perpendicular to the vertical direction V. The stress relief feature 218 may form a gap or pocket between the mold bottom 214 and the top surface of the lifter projection 246 at the center of the stress relief feature 218. In other words, only an outer peripheral ring of the top surface of the lifter projection 246 may come into contact with the mold bottom 214, and the gap or pocket may be provided within the outer peripheral ring. When the lifter arm 242 moves in the vertical direction V to deform the flexible mold 210, the mold bottom 214 may deform in the lateral direction L and the transverse direction T to spread across the top surface of the lifter projection 246 (e.g., the gap or pocket may collapse). Therefore, stress on the flexible mold 210 may be reduced, in turn reducing material fatigue and failure and prolonging a life of flexible mold 210.

Referring to FIGS. 9 and 10, the mold assembly 400 may be removably accommodated within the receiving chamber 350 of the housing 310. FIG. 9 illustrates the mold assembly 400 fully inserted into the receiving chamber 350. FIG. 10 illustrates the mold assembly 400 fully removed from the receiving chamber 350.

According to one example embodiment, the flexible mold 210 may include one or more mold cavities 212. According to another example embodiment, the one or more mold cavities 212 may be predominantly square in shape and may have a flat bottom surface. It should be appreciated that any number of molds having any viable three-dimensional shaped mold cavities 212 may be provided. In this manner, a user may remove a first removable mold assembly 400 having a mold cavity 212 with a first shape and insert a second removable mold assembly 400 having a mold cavity 212 with a second shape. Thus, a different shape of ice may be produced according to a desire of the user.

Further, it should be appreciated that the lifter mechanism 240 may be connected to the housing 310 as opposed to the mold assembly 400. For instance, the lifter arm 242, lifter projection 246, and roller axle 284 may be separated from the removable mold assembly 400 and provided within the receiving chamber 350. One or more grooves may be formed in the mold support 220 through which the lifter arm 242 passes when the mold assembly 400 is inserted into the receiving chamber 350 of ice making assembly 200.

According to an example embodiment, a distinct removable mold assembly includes a flexible rubber mold, mold support, frame, and lifter assembly, may be removed from an icemaker. The rubber mold is then removed by pulling out on the removable mold. To change the ice shape, a new distinct mold with a different rubber mold cavity shape is inserted into the icemaker. The mold support permits the flow of cooling air in order to convection cool the mold and form ice.

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.

SYSTEMS FOR ICE MOLD ASSEMBLIES IN ICE MAKER APPLIANCES

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