ICE MAKING ASSEMBLY FOR A REFRIGERATOR APPLIANCE

Description

FIELD OF THE INVENTION

The present subject matter relates generally to refrigerator appliances, and more particularly to ice making assemblies for a refrigerator appliance.

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 refrigerator appliances may also include twist tray icemakers mounted on the freezer door. However, as the refrigerator doors are opened and closed, unfrozen water on the icemaker tray may tend to spill over the tray into the ice bucket, the door inner surface, and/or into the freezer cabinet. The water splash/spill not only impacts the quantity and quality of the ice produced but leads to potential ice clumping in the ice bucket and ice flakes on the inner wall of the freezer door. In addition, the twist tray may require room to rotate and twist to harvest ice, which makes it harder to design a rigid wall around the tray that could prevent the water spillage in a traditional (stationary) *icemaker configuration. In this regard, if a rigid wall is built around the twist tray to contain the water, twist tray could be interfering and rubbing against the wall during harvest/homing cycles. This interference could lead to plastic chips/flakes/powder from the contact wear between tray and rigid wall falling into the ice tray. Another problem faced by twist tray ice makers, particularly with large size cubes, is the higher ice-adhesion force that the motor has to overcome during harvest.

Accordingly, a refrigerator appliance with features for improved ice making would be desirable. More particularly, an ice making assembly that includes spill reducing features and facilitates an improved harvesting process would be particularly beneficial.

BRIEF DESCRIPTION OF THE INVENTION

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

In one exemplary embodiment, a refrigerator appliance defining a vertical direction, a lateral direction, and a transverse direction is provided, including a cabinet defining a chilled chamber, a door rotatably mounted to the cabinet and rotatable between a closed position enclosing the chilled chamber and an open position providing access to the chilled chamber, and an ice making assembly mounted to the door of the refrigerator appliance. The ice making assembly includes an icemaker frame mounted to the door, an ice tray rotatably mounted to the icemaker frame and defining a plurality of mold cavities for receiving water that is formed into ice, a drive motor operably coupled to the ice tray to rotate the ice tray and harvest the ice formed within the plurality of mold cavities, and a splash shield extending from a top edge of the ice tray to prevent splashing from the plurality of mold cavities.

In another exemplary embodiment, an ice making assembly mounted to a door of a refrigerator appliance is provided. The ice making assembly includes an icemaker frame mounted to the door, an ice tray rotatably mounted to the icemaker frame and defining a plurality of mold cavities for receiving water that is formed into ice, a drive motor operably coupled to the ice tray to rotate the ice tray and harvest the ice formed within the plurality of mold cavities, and a splash shield extending from a top edge of the ice tray to prevent splashing from the plurality of mold cavities.

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 front view of the example 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 front 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 perspective view of an ice tray of the example ice making assembly of FIG. 3 according to an example embodiment of the present subject matter.

FIG. 5 provides a cross-sectional view of the example ice making assembly of FIG. 3 according to an example embodiment 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 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 or spirit 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.

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 and/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 and/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.

As explained herein, aspects of the present subject matter are generally directed to an ice tray that includes a flexible rubber piece over molded to its top, sides, and bottom to prevent water splashing and provide insulation. This design promotes top-to-bottom freezing, aiding in the self-release of ice cubes. The over molding ensures the rubber stays securely attached during twisting, preventing separation and stuck cubes. Raised angular walls may direct water back into the tray, further minimizing splashes and enhancing overall ice harvesting efficiency.

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 such as, 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 front 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 and/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 will be described according to exemplary embodiments of the present subject matter. Dispensing assembly 140 is generally configured for dispensing liquid water and/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.

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 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.

Referring again to FIG. 2, inside refrigerator appliance 100, freezer door 130 may include an ice dispensing system 150 that generally includes one or more icemakers and ice storage bins 152 that are configured to form ice. In this regard, for example, ice dispensing system 150 may define an ice making chamber 154 for housing ice making assemblies, storage mechanisms, and dispensing mechanisms. According to the illustrated embodiment, ice dispensing system 150 may include dispensing assembly 140 and may have a main icemaker 156. In addition, ice dispensing system 150 may include an icemaker for forming “craft ice” that is commonly large, clear cubes or spheres of ice for alcoholic or non-alcoholic drinks. For example, a user may access this craft ice by opening freezer door 130 and accessing storage bin 152 directly.

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 specifically to FIGS. 3 through 5, icemaker 156 will be described in more detail according to example embodiments of the present subject matter. According to the illustrated embodiment, icemaker 156 is mounted to freezer door 130 of refrigerator appliance 100. As explained briefly above, rapid opening and/or closing of freezer door 130 may result in water spilling from icemaker 156, where it may have a tendency to freeze over and form ice buildup, jam the icemaker, or damage refrigerator appliance 100 and/or surrounding surfaces. Accordingly, aspects of the present subject matter are directed to features of icemaker 156 that may prevent or eliminate such spillage. Although an exemplary construction is described herein, it should be appreciated that variations and modifications may be made while remaining within the scope of the present subject matter.

As shown, icemaker 156 may generally include an icemaker frame 200 that is mounted to freezer door 130, e.g., within ice dispensing system 150. In general, icemaker frame 200 is a substantially rigid structure that is fixed in position to freezer door 130. Icemaker frame 200 may include one or more structures that are coupled for supporting various components of icemaker 156 as described herein. For example, icemaker 156 may further include an ice tray 202 that is rotatably mounted to icemaker frame 200 and which defines a plurality of mold cavities 204 for receiving water that is formed into ice during the ice production process. In this regard, refrigerator appliance 100 may include a water fill spout 206 that may be used to selectively dispense water into mold cavities 204 to facilitate ice formation.

According to the illustrated embodiment, ice tray 202 is a twistable ice tray that is distorted in order to facilitate the release of ice. In this regard, ice tray 202 may be rotatable between a first position or the “home position” or “ice making position” (e.g., as shown for example in FIGS. 3 and 5) where water fill spout 206 may be used to fill mold cavities 204 with liquid water. During the harvest process, ice tray 202 may be rotated within icemaker frame 200 by a drive motor 210 and icemaker frame 200 may further include a structural stop (not shown) that engages ice tray 202 to prevent localized rotation at one or more locations, thus resulting in the twisting of ice tray 202. This position may be referred to herein generally as the “harvest position.” Accordingly, as drive motor 210 continues to rotate ice tray 202, structural stop causes ice tray 202 to twist and deform the mold cavities 204 in a manner that releases the ice cubes.

Notably, due to the tight tolerances between ice tray 202 and icemaker frame 200, conventional ice making assemblies may result in rubbing between the rotating ice tray 202 and icemaker frame 200. This rubbing and interaction between these two components may cause plastic chips, flakes, and or powder to fall into ice tray 202, into storage bin 152, or may otherwise result in undesirable wear to icemaker 156. Accordingly, icemaker 156 may generally define a clearance or gap 212 that is defined between ice tray 202 and icemaker frame 200 throughout rotation of ice tray 202. However, this gap 212 may provide an avenue for water to spill out of ice tray 202 and down into storage bin 152 or other areas of refrigerator appliance 100.

Accordingly, icemaker 156 may further include one or more resilient splash shields 220 that are generally positioned between icemaker frame 200 and ice tray 202 to prevent splashing from the plurality of mold cavities 204. Although an example positioning and construction of resilient splash shields 220 are described herein, it should be appreciated that the size, positioning, construction, and configuration of resilient splash shields 220 may vary while remaining within the scope of the present subject matter. In general, resilient splash shields 220 may be formed from any suitably resilient material that may deflect upon engaging or interacting with icemaker frame 200 and/or ice tray 202. For example, resilient splash shields 220 may be formed from an elastomeric material, such as silicone or another suitable rubber.

According to the illustrated example embodiment, resilient splash shield 220 extends from a top edge 222 of ice tray 202. For example, top edge 222 may define a receiving surface for securely engaging resilient splash shield 220, e.g., thereby providing a surface upon which resilient splash shield 220 may be over molded. According to the illustrated embodiment, resilient splash shield 220 may be positioned around an entire perimeter 224 of ice tray 202, while according to alternative embodiments splash shield 220 may be localized or lengthened in areas where splashing is more likely.

In addition, according to an example embodiment, splash shield 220 extends upward toward a center of ice tray 202 at an extension angle 226 measured relative to a horizontal plane (e.g., a plane defined by the lateral direction L and the transverse direction T). In this manner, sloshing water may have a tendency to be directed back into ice tray 202. According to an example embodiment, extension angle 226 may be between about 45 and 85 degrees, between about 50 and 70 degrees or about 60 degrees, measured relative to the horizontal plane. It should be appreciated that according to alternative embodiments, resilient splash shield 220 may also have different geometries to facilitate splash reduction, e.g., such as a curved splash shield.

Referring still generally to FIGS. 3 through 5, icemaker 156 may further include an insulation layer 230 that covers a bottom surface 232 of ice tray 202. In this regard, for example, insulation layer 230 may be an insulating material that is over molded or otherwise attached directly to bottom surface 232 of ice tray 202. According to an example embodiment, splash shield 220 and insulation layer 230 are formed as a single, integral piece. For example, these components may be molded onto ice tray 202 in a single over molding operation. As illustrated, insulation layer 230 may fully surround bottom surface 232 of ice tray 202, e.g., thereby facilitating top down freezing of ice within ice tray 202. Notably, top-down freezing may result in ice cubes having improved clarity and may also facilitate improved ice cube harvesting from ice tray 202.

As mentioned above, an over molding process may be used to attach splash shield 220 and insulation layer 230 to ice tray 202. For example, according to exemplary embodiments, ice tray 202 may be formed by injection molding, e.g., using a suitable plastic material, such as injection molding grade polypropylene, Polybutylene Terephthalate (PBT), Nylon 6, high impact polystyrene (HIPS), acrylonitrile butadiene styrene (ABS), or any other suitable blend of polymers. Alternatively, according to the exemplary embodiment, these components may be compression molded, e.g., using sheet molding compound (SMC) thermoset plastic or other thermoplastics. After ice tray 202 is formed, splash shield 220 and insulation layer 230 may be added using any suitable over molding procedure.

It should be appreciated that resilient splash shields 220 and/or insulation layer 230 may be mounted to ice tray 202 in any suitable manner to prevent splashing from ice tray 202, e.g., when freezer door 130 is moved rapidly between the open and closed positions. For example, according to the alternative embodiments, resilient splash shields 220 and insulation layer 230 may be separate components that are snapped into recesses or complementary features defined on ice tray 202. Other suitable methods of mounting resilient splash shields 220 and insulation layer 230 are possible and within the scope of the present subject matter.

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 language of the claims.