ICE MAKING APPLIANCE

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 19/339,863 filed on Sep. 25, 2025, which in turn claims the benefit of U.S. Provisional Application No. 63/724,753 filed Nov. 25, 2024, the disclosures of which are hereby incorporated in their entirety by reference herein.

TECHNICAL FIELD

The present disclosure relates to an appliance such as a refrigerator.

BACKGROUND

In order to promote ice production, a low temperature must be supplied and maintained to freeze water molecules. Refrigerators circulate refrigerant and change the refrigerant from a liquid state to a gaseous state by an evaporation process in order to cool the air within the ice making compartment. This colder air produces ice that is typically in various shapes such as cubes and trapezoids, which are frozen into relatively large solid sizes, making them difficult to chew. Current chewable ice making products are directed to commercial large quantity production or counter-top ice or stand-alone ice makers.

SUMMARY

A refrigerator appliance includes a door, a first ice maker, a second ice maker, and a dispenser. The door defines an internal compartment. The first ice maker is disposed within the internal compartment and is operable to produce solid ice. The second ice maker is disposed within the internal compartment and is operable to produce chewable ice. The dispenser is positioned on an exterior of the door. The dispenser is in communication with the internal compartment. The dispenser is operable to dispense the solid ice and the chewable ice from the internal compartment.

An ice making system for refrigerator appliance includes a first ice maker, a second ice maker, and a cooling system. The first ice maker is operable to produce solid ice and to direct the solid ice to a dispenser. The second ice maker is disposed within a shared compartment with the first ice maker. The second ice maker is operable to produce chewable ice and to direct the chewable ice to the dispenser. The cooling system is operable to supply cooling air at a first temperature to the first ice maker and to supply cooling air at a second temperature to the second ice maker.

An ice making system for refrigerator appliance includes a first ice maker, a second ice maker, and a cooling system. The first and second ice makers are disposed within a shared compartment and are operable to produce solid and chewable ice, respectively. The cooling system has a first duct, a first damper, a second duct, and a second damper. The first duct is in fluid communication with the shared compartment and is operable to direct cooling air at a first temperature to the first ice maker. The first damper is disposed with the first duct to facilitate and restrict airflow to the first ice maker. The second duct is in fluid communication with the shared compartment and is operable to direct cooling air at a second temperature to the second ice maker. The first temperature is less than the second temperature. The second damper is disposed within the second duct to facilitate and restrict airflow to the second ice maker.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top front perspective view of a refrigerator with a chewable ice maker in phantom according to an aspect of the disclosure discussed herein;

FIG. 2 is a top rear perspective view of the refrigerator of FIG. 1 with an exterior wrapper removed to reveal a refrigerator compartment, a freezer compartment, an ice maker, an evaporator housing, and a duct assembly according to an aspect of the disclosure discussed herein;

FIG. 3 is a top front perspective view of the duct assembly of FIG. 2 as coupled to the ice maker and disposed within a sidewall shown in phantom according to an aspect of the disclosure discussed herein;

FIG. 4 is a front perspective view of an exemplary ice making system configured in a housing according to an aspect of the disclosure discussed herein;

FIG. 5 is a partial exploded view of an exemplary ice maker assembly according to an aspect of the disclosure discussed herein;

FIG. 6 is a partial exploded view of an exemplary ice making extruder assembly according to an aspect of the disclosure discussed herein;

FIG. 7 is a partial exploded view of an alternative exemplary ice making extruder assembly according to an aspect of the disclosure discussed herein;

FIG. 8 is a front view of an exemplary ice making system with the housing and a front cover removed and exposing components of the ice making extruder assembly according to an aspect of the disclosure discussed herein;

FIG. 9 is a side perspective view of the ice making system of FIG. 8 illustrating the ice bin assembly and the ice discharge assembly according to an aspect of the disclosure discussed herein;

FIG. 10A is a partial exploded front perspective view of the ice bin assembly of FIG. 9 according to an aspect of the disclosure discussed herein;

FIG. 10B is a partial exploded front perspective view of the ice bin assembly of FIG. 9 according to another aspect of the disclosure discussed herein;

FIG. 11 is a front perspective view of the ice discharge assembly of FIG. 9 according to an aspect of the disclosure discussed herein;

FIG. 12A is a front view of an exemplary “Z” shaped auger arm according to another aspect of the disclosure discussed herein;

FIG. 12B is a front view of an exemplary “comb” auger arm according to another aspect of the disclosure discussed herein;

FIG. 12C is a front view of an exemplary “flat beater” shaped auger arm according to another aspect of the disclosure discussed herein;

FIG. 12D is a cross-sectional view taken along line D-D in FIG. 12C;

FIG. 13 is a top cross-sectional view of an exemplary ice maker assembly illustrating air flow path according to an aspect of the disclosure discussed herein;

FIG. 14 is a schematic view of an ice making system that includes both a solid ice maker and a chewable ice maker that are each disposed within a shared space within a door of the refrigerator;

FIG. 15 is a schematic view of an alternative configuration of the ice making system illustrated in FIG. 14;

FIG. 16 is a schematic front view of the door of the refrigerator illustrating a dispenser of the ice making system;

FIG. 17 is an internal view of a lower end of the ice bin assembly including an auger arm and ice crushing blades;

FIG. 18 is a schematic front view of the refrigerator door and a solid ice maker positioned within the door, where the solid ice maker is part of a first alternative configuration of the ice making system that includes both the solid ice maker and the chewable ice maker;

FIG. 19 is a front perspective view of the refrigerator compartment and a chewable ice maker disposed within the refrigerator compartment, where the chewable ice maker is part of the first alternative configuration of the ice making system that includes both the solid ice maker and the chewable ice maker;

FIG. 20 is a side view of the refrigerator with an exterior wrapper removed to reveal a duct system that is operable to direct air to both the both the solid ice maker and the chewable ice maker depicted in FIGS. 18 and 19, respectively;

FIG. 21 is a front schematic view of the refrigerator and a second alternative configuration of the ice making system that includes both the solid ice maker and the chewable ice maker where the solid ice maker and the chewable ice maker are operable to deliver ice to separate drawers;

FIG. 22 is a side schematic view of the refrigerator and the second alternative configuration of the ice making system;

FIG. 23 is a top schematic view of the refrigerator and the second alternative configuration of the ice making system;

FIG. 24 is a schematic front view of an alternative configuration of the refrigerator appliance having a chewable ice maker disposed within the freezer compartment and an ice storage bin disposed in the refrigerator compartment;

FIG. 25 is a schematic detailed view of the chewable ice maker and ice storage bin depicted in FIG. 24;

FIG. 26 is a front cross-sectional view of an alternative configuration of the lower portion of the ice bin assembly;

FIG. 27 front isometric cross-sectional view of the alternative configuration of lower portion of the ice bin assembly;

FIG. 28 is a top view of the alternative configuration of lower portion of the ice bin assembly;

FIG. 29 is a top view of a dispensing zone within the lower portion of the ice bin assembly;

FIG. 30 is a bottom isometric view of the chute plate illustrating the positioning of a melt water tank;

FIG. 31 is a partial exploded view illustrating the chute plate and the melt water tank;

FIG. 32 is a cross-section view of the melt water tank;

FIG. 33 is a schematic diagram illustrating a water management system for the chewable ice maker; and

FIG. 34 is flowchart illustrating the coordinated operation of the chewable ice maker and the water management system.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures may be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the disclosure as oriented in FIG. 1. Unless stated otherwise, the term “front” shall refer to the surface of the element closer to an intended viewer, and the term “rear” shall refer to the surface of the element further from the intended viewer. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

The terms “including,” “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by “comprises a . . . ” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

Aspects of the disclosure herein relate to a refrigerator appliance that includes a chewable ice making and dispensing system configured within an exterior door of the refrigeration appliance. The refrigerator cooling system is configured to cool the chewable ice making and dispensing system. The chewable ice making system includes an ice making cavity having a screw auger disposed within. Water is injected into the ice making cavity and the cooling system supplies cooling air to a plurality of stacked fins positioned radially around the ice making cavity. An insulation housing is sealed around the plurality of stacked fins providing an isolated cooling chamber for directing the cooling air around and through the plurality of stacked fins. The cooling system continues to supply cooling air during the ice making process while the water supply is maintained to provide enough water to form ice once the water comes in contact with the chilled walls of the ice making cavity. As ice is formed, the rotating screw, driven by a drive motor, scrapes the ice off the cavity walls to form ice flakes or chips, which are carried by the screw toward an ice making extruder where the ice flakes or chips are compacted to a chewable density and forced out of the ice making cavity in the form of cylinders. The cylinders come in contact with a breaking element positioned above the extruder and configured to break the newly formed chewable ice cylinders into smaller ice pellets. The chewable ice may also be referred to as nugget ice.

Once the chewable ice pellets are separated, the process of making ice continues to force more chewable ice cylinders out of the extruder and the abundance is slid down a sloped ice chute and into a storage bin. The storage bin is configured to rotate an auger arm to keep the chewable ice pellets from clumping prior to dispensing through the dispenser. The storage bin may include apertures or slots to direct a supply of cold air across the ice keeping it cool and frozen. However, since chewable ice is less dense creating a lower melt temp as compared to regular ice cubes, stored chewable ice results in melt water forming in the base of the storage bin.

In another aspect of the disclosure discussed herein a water recirculation system is included to capture and reuse the melt water. A filtration and sanitizer may be included to prevent contaminants from being introduced into the ice making process from the melted ice. Additionally, an ultraviolet light may be used within the water recirculation system and the ice storage bin to further sanitize the ice before use. The water recirculation system may include a melt water sump fluidly connected to a valve and a pump, to move the water to refill the ice making water storage tank. A separate pump and valve may be used to fill the ice making chamber from the ice making water storage tank. Alternatively, the melt water may be sent to the evaporator via a drain line.

A controller can be configured to receive information related to a request for ice production by a user selecting the contacting paddle or push button positioned at the front of the refrigerator door and sending a signal to the controller to request ice. Once the controller receives the ice request and receives a signal from a presence sensor or a command for automatic fill, ice will be dispensed. Once ice is dispensed, thereby lowering the level of ice in the storage bin below a predetermined level, a sensor notifies the controller, and the controller activates the ice maker to start the process of making ice over. Additionally, since chewable ice is softer, and a percentage will melt during storage, the ice maker may be activated based on the volume of ice melt detected by the level sensors. Alternatively, activation may also be calculated based on time of flow rates out of the ice dispenser and refill activated by those control calculations. Alternatively, the controller may activate the water source based on availability and volume of water sensed in the melt water sump and provided a constant pressure is maintained as the water is introduced into the ice making chamber.

In another aspect of the disclosure discussed herein the controller may receive a signal from a variety of temperature sensors, presence sensors or other sensors positioned along the ice making process, these sensors communicate parameters for requesting cool air from the cooling system or additional water for the ice making cavity to allow for proper ice cooling and compaction.

Referring to the embodiment illustrated in FIG. 1, reference numeral 10 generally designates a refrigerator (e.g., a refrigerator appliance) having a cabinet structure 13 with a front surface 14 opening into a refrigerator compartment 12. The cabinet structure 13 may include a vacuum insulated cabinet structure, as further described below. The refrigerator compartment 12 is contemplated to be an insulated portion of the cabinet structure 13 for storing fresh food items. First and second doors 18, 20 are rotatably coupled to the cabinet structure 13 near the front surface 14 thereof for selectively providing access to the refrigerator compartment 12 by pivoting movement between open and closed positions. In the embodiment shown in FIG. 1, a freezer drawer 22 is configured to selectively provide access to a freezer compartment 24 disposed below the refrigerator compartment 12. The refrigerator 10 shown in FIG. 1 is an exemplary embodiment of a refrigerator for use with the present concept and is not meant to limit the scope of the present concept in any manner.

As further shown in FIG. 1, the first door 18 includes a dispensing station 2 which may include one or more paddles 4, 6 which are configured to initiate the dispensing of water and/or ice from outlets disposed within the dispensing station 2. Alternatively, a push button or a sensor system (not illustrated) may be utilized for the dispensing of ice and/or water in place of the paddles 4, 6, as well as any combination thereof. In the embodiment shown in FIG. 1, the dispensing station 2 is shown as being accessible from outside of the refrigerator 10 on an exterior portion of the first door 18 but may also be provided along any portion of the refrigerator 10, including an interior of the refrigerator compartment 12, for dispensing ice and/or water. The dispensing station 2 is contemplated to be coupled to a chewable ice making system 200, which is shown in phantom in FIG. 1. The chewable ice making system 200 may be referred to as the chewable ice maker or the chewable nugget ice maker. It is contemplated that the chewable ice making system 200 may be operably coupled to the first door 18 to pivotally move with the first door 18 between open and closed positions. As further shown in FIG. 1, the cabinet structure 13 of the refrigerator 10 includes an exterior wrapper 32 which includes first and second sidewalls 34, 36, a top wall 38 and a rear wall 40. The exterior wrapper 32 is contemplated to be a metal component formed of a sheet metal material. The cabinet structure 13, or more specifically the exterior wrapper 32 of the cabinet structure 13, defines an internal cavity 41 that houses all of the internal components of the refrigerator 10. The refrigerator compartment 12 and the freezer compartment 24 may be considered to be portions of the internal cavity 41.

Referring now to FIG. 2, the refrigerator 10 is shown with the cabinet structure 13 removed to reveal the refrigerator compartment 12 disposed over the freezer compartment 24. The components illustrated in FIG. 2, other than the exterior facing portions of the doors 18, 20, 22 are disposed within the internal cavity 41. The refrigerator compartment 12 is generally defined by a refrigerator liner 42 which includes first and second sidewalls 44, 46, a top wall 48, a rear wall 50 and a bottom wall 52. The freezer compartment 24 also includes a freezer liner 53 having first and second sidewalls 54, 56, a top wall 58, a rear wall 60 and a bottom wall 62. The refrigerator liner 42 and freezer liner 53 may be composed of a sheet metal material or a polymeric material. As encapsulated by the exterior wrapper 32, the refrigerator liner 42 and the freezer liner 53 are spaced-apart from the exterior wrapper 32 to define an insulating space 66 (FIG. 3) therebetween, which may include a vacuum insulated space. The combination of the first sidewall 44 of the refrigerator liner 42 and the first sidewall 54 of the freezer liner 53 is represented by reference numeral 35 for ease in defining the internal parameter of the insulating space 66. Thus, the exterior wrapper 32 and the refrigerator liner 42 and freezer liner 53 may be interconnected by a trim breaker to define the overall cabinet structure 13 of the refrigerator 10.

With further reference to FIGS. 2 and 3, a cooling system 67, or air cooling system, is shown that is operable to provide cold air to the refrigerator compartment 12, the freezer compartment 24, and the chewable ice making system 200. An evaporator housing 64 is shown disposed on or adjacent to the rear wall 60 of the freezer liner 53. The evaporator housing 64 houses a heat exchanger, such as an evaporator 69, that is part of the cooling system 67, that cools and provides cold air to the chewable ice making system 200. In FIG. 2, the evaporator 69 is concealed by an evaporator housing cover 65. It is contemplated that cold air may be drawn from the evaporator housing 64 for cooling the refrigerator compartment 12 and/or freezer compartment 24 as well. As positioned on this side of the cabinet structure 13, the insulating space 66 is configured to house a duct system or duct assembly 70 of the cooling system 67 that interconnects the chewable ice making system 200 and an evaporator housing 64. The duct assembly 70 is configured to be concealed within the insulating space 66, as best shown in FIG. 3. The duct assembly 70 includes an ice maker feed duct 72 having first and second ends 74, 76 with a body portion 78 disposed therebetween. The body portion 78 is a substantially linear body portion that defines an ascending airway between the evaporator housing 64 and the chewable ice making system 200. The duct assembly 70 further includes an ice maker return duct 82. The ice maker return duct 82 includes a first end 84 coupled to the chewable ice making system 200, and a second end 86 coupled to the evaporator housing 64. The ice maker return duct 82 further includes a body portion 88 disposed between the first and second ends 84, 86 that defines a substantially linear descending airway between the chewable ice making system 200 and the evaporator housing 64. The ice maker feed duct 72 and the ice maker return duct 82 may be referred to as first and second ducts, respectively, or vice versa. The ice maker feed duct 72 and the ice maker return duct 82 may also be referred to as primary ducts.

As used herein, the terms “substantial,” “substantially,” and variations thereof are intended to note that a described feature is equal or approximately equal to a value or description. For example, a “substantially linear” feature is intended to denote a feature that is linear or approximately linear. Moreover, “substantially” is intended to denote that two values are equal or approximately equal. In some embodiments, “substantially” may denote values within about 10% of each other, such as within about 5% of each other, or within about 2% of each other. As such, the substantially linear body portions 78, 88 of the ice maker feed duct 72 and the ice maker return duct 82, respectively, are contemplated to be substantially straight or linear body portions that interconnect the evaporator housing 64 with the chewable ice making system 200 in a direct and un-convoluted manner.

The duct assembly 70 is shown disposed within the insulating space 66 of the cabinet structure 13. The duct assembly 70, including ice maker feed duct 72 and the ice maker return duct 82, may be disposed within a single sidewall of the cabinet structure 13. This configuration helps to directly feed cold air from the evaporator housing 64 to the chewable ice making system 200. In FIG. 3, the evaporator housing cover 65 (FIG. 2) has been removed from the evaporator housing 64 to reveal first and second portions 64A, 64B of the evaporator housing 64. In the second portion 64B of the evaporator housing 64, the evaporator (not illustrated) is disposed and concealed by an evaporator plate 81. In the first portion 64A of the evaporator housing 64, first and second fans 100, 102 of the cooling system 67 are shown. The first fan 100 is configured to feed cold air to the freezer compartment 24 during a freezer compartment cooling cycle. As such, the first fan 100 may be referred to herein as a freezer compartment fan. The first fan 100 is connected in-series to the second fan 102, as further described below. Thus, the first fan 100 provides cold air not only to the freezer compartment 24, but also provides cold air from the evaporator (not illustrated) to the second fan 102 as well. The second fan 102 provides cold air from the first fan 100 to the chewable ice making system 200 via the duct assembly 70 during an ice making cycle. As such, the second fan 102 may be referred to herein as an ice maker fan. Thus, the first and second fans 100, 102 are operable between active and at-rest conditions, and the fans 100, 102 are running in the active condition and are not running in the at-rest condition. The condition of the first and second fans 100, 102 is controlled by a controller of the refrigerator 10, as further described below, which also controls the various cycles of the refrigerator 10 and an ice making process and distribution process.

As further shown in FIGS. 3 and 4, the chewable ice making system 200 includes an air supply inlet 104 and a return air outlet 106. As illustrated, the ice maker feed duct 72 is interconnected between the evaporator housing first portion 64A, at the first end 74 of the ice maker feed duct 72, and the chewable ice making system 200, at the air supply inlet 104, at the second end 76 of the ice maker feed duct 72. As further illustrated in FIG. 3, the ice maker return duct 82 is interconnected between the chewable ice making system 200, at the return air outlet 106, at the first end 84 of the ice maker return duct 82, and evaporator housing 64, at the second portion 64B thereof, at the second end 86 of the ice maker return duct 82. Thus, it is contemplated that the second fan 102 supplies cold air from the evaporator housing 64 to the chewable ice making system 200 via the ice maker feed duct 72 of the duct assembly 70. The cold air powered by the second fan 102 is fed into the air supply inlet 104 of the chewable ice making system 200 by the ice maker feed duct 72. Cooling air or cold air 114 is sent around a plurality of cooling fins 291 configured on an outside of an ice making cylinder 244 (which will be described in greater detail below) and through the return air outlet 106 and returned to the second portion 64B of the evaporator housing 64 by the ice maker return duct 82 for recycling. In this way, the ice maker return duct 82 provides cold air to the evaporator housing 64 near the evaporator (not illustrated), such that the evaporator can use the cold air leftover from an ice making process when providing cold air to the first fan 100. This results in an overall energy savings for the cold air producing process of the evaporator (not illustrated). Both the ice maker feed duct 72 and the ice maker return duct 82 are contemplated to be insulated ducts, as they are configured to carry much colder air as compared to cold air provided to the refrigerator compartment 12 (FIGS. 1-2). The ice maker feed duct 72 and the ice maker return duct 82 are contemplated to be insulated by a gas impervious barrier having an insulating material, such that the super cooled air carried in the ice maker feed duct 72 and the ice maker return duct 82 is not diffused into other components of the refrigerator 10 along the travel path between the evaporator housing 64 and the chewable ice making system 200.

Turning now to FIG. 4, an exemplary chewable ice making system 200 is illustrated with a door liner 210 (FIG. 3), which is typically disposed around an outer periphery of a housing 202 of the chewable ice making system 200, and door 18 removed. The housing 202 contains an ice maker assembly 204, an ice bin assembly 206, and an ice discharge assembly 208. The chewable ice making system 200 is configured to be positioned within the first door 18 as a single unit and is removably connected to a cavity positioned in the door liner 210. The removability provides access to the chewable ice making system 200 for maintenance of the components of the chewable ice making system 200. An ice maker door 212 (FIG. 3) is included to seal off the chewable ice making system 200 from the refrigerator compartment 12 when the door 18 is in the closed position and from the outside air when the door 18 is in the open position. The ice maker door 212 includes a seal (not illustrated) and a latch 214, to close off the chewable ice making system 200 to further limit temperature fluctuations due to the delta between the super cooled air in the ice maker assembly 204 and the higher temperatures in the ambient air of the refrigerator compartment 12 or the outside air.

FIG. 4 further illustrates the ice maker assembly 204 and the ice bin assembly 206 positioned within the housing 202 while the ice discharge assembly 208 is positioned beneath the housing 202. An inlet water line 216 has a water supply end 218 and a tank end 220. The inlet water line 216 extends above and through the housing 202 to supply water to a primary or first water storage tank 222 (FIG. 5). The inlet water line 216 may extend from a refrigerator water supply line fluidically coupled at the water supply end 218 and extending from a filter system (not illustrated) to supply filtered water to the first water storage tank 222 coupled and fluidically coupled to the tank end 220. Alternatively, the filter system may provide filtered water to a refrigerator water tank (not illustrated) that is fluidically coupled through the inlet water line 216 water supply end 218 to provide filtered water to the first water storage tank 222. This may help to maintain a steady flow of water to the first water storage tank 222. Additionally, the inlet water line 216 may include a separate filter assembly (not illustrated) to provide an additional filtering of the water entering the first water storage tank 222. The inlet water line 216 and the refrigerator water tank may be configured in the insulating space 66 (FIG. 3) with the inlet water line 216 exiting through an aperture (not illustrated) in the refrigerator top wall 38 and extending through a door hinge 221 (FIG. 1) and into the door liner 210 before extending through the housing 202 and into the first water storage tank 222.

As used herein, the terms “fluidically coupled”, “fluidically connected”, “fluidically interconnected”, “fluidly coupled”, “fluidly connected” or “fluidly interconnected” indicate that two or more structures are connected to one another in such a way as to provide for fluid air flow or water flow between the two or more structures. Said differently, an airway interconnects the two or more structures, such as the duct assembly 70 fluidically interconnecting the chewable ice making system 200 and the evaporator housing 64. Also as used herein, the term “in-series” indicates two or more structures that are serially aligned along an airway, such as the first and second fans 100, 102. Additionally, a waterline interconnects the two or more structures, such as the inlet water line 216 fluidically interconnecting the refrigerator water filtration and storage system (not illustrated) and the first water storage tank 222, and an ice maker water line 228 fluidically interconnecting the first water storage tank 222 at a first end 230 to the ice maker assembly 204 at a second end 232. The second end 232 is fluidically coupled to a water inlet 240 (FIG. 8) extending from at least a portion of an ice making cylinder base 242.

Referring now to FIG. 5, an exemplary ice maker assembly 204 is illustrated in a partial exploded view. The components of the ice maker assembly 204 may include an ice maker assembly frame 266, configured to receive an ice making extruder assembly 268 and the first water storage tank 222. The assembly frame 266 is configured to provide support and structure for the ice making extruder assembly 268 and the water supply system connected to the first water storage tank 222, which will be discussed in greater detail below. The assembly frame 266 also provides a support wall 267 for mounting an air duct housing 92 that is attached to a surface of the support wall 267, the air duct housing 92 is configured to receive and provide a sealing surface for the ice maker feed duct 72, and the ice maker return duct 82 to mount to, as discussed above. Alternatively, the air duct housing 92 may mount directly to the housing 202 and a conduit may be configured between the housing 202 and the support wall 267 to create a sealed flow path for the super cold treated air to flow into the ice making extruder assembly 268.

Turning now to FIG. 6 a partial exploded view of another configuration of the ice making extruder assembly 268 is illustrated. It is noted that the ice making extruder assembly 268 as illustrated in FIG. 7 may have the same elements and structure the as ice making extruder assembly 268 illustrated in FIG. 6, unless otherwise stated or illustrated herein. The components of the ice making extruder assembly 268 may include an ice making drive motor 248 that is configured to be positioned on and removably affixed to the ice maker assembly frame 266. The assembly frame 266 provides rigidity and support to the ice making extruder assembly 268 when assembled. As further illustrated, the ice making extruder assembly 268 may include the ice making cylinder base 242 configured to couple with the drive motor 248 on a first side and the ice making cylinder 244 on an opposite second side. The ice making cylinder base 242 may include a bearing assembly 278 and the water inlet 240. By way of a non-limiting example, the bearing assembly 278 may include an axial bearing, a thrust bearing or other similar bearing. The bearing assembly may also include a plurality of seals 190, O-rings 191, and distance rings 192 to provide a sealing engagement between the bearing assembly and the other ice making extruder assembly 268 components. Additionally, seals, O-rings and distance rings may also be used when assembling the ice making extruder assembly 268 to further align the components, maintaining an axial gap and creating a watertight assembly. It should be understood that the water inlet 240 may also be configured in a wall, outer surface, or external surface 245 of the ice making cylinder 244.

Next the ice making screw 246 (which may also be an ice making scraper and/or auger) is inserted into an internal cavity 247 defined by the ice making cylinder 244. The internal cavity 247 may be referred to as the extruding ice maker cavity or as the ice making cavity. The ice making screw 246 may include a first end 272, a screw body 274, and a second end 276. The first end 272 is configured to be inserted into the bearing assembly 278 and is configured to couple to the drive motor 248, so that the drive motor 248 may rotate the ice making screw 246 during the ice making process to transition the ice making water across an ice making zone (e.g., an inner surface 282 of the ice making cylinder 244 or a portion of the inner surface 282) to form ice crystals or flakes. The ice maker screw 246 second end 276 may also include a bushing or bush bearing 280. The bush bearing 280 is configured to be received in an extruder head 254 to further aid in the smooth rotation of the ice making screw 246. The extruder head 254 may also be referred to as the extruder body, extruder plate, extruder die, die, or extruder. The extruder head 254 includes a plurality of extrusion apertures or through extrusion apertures 255. The extruder head 254 may comprise a die that is operable to form a material (e.g., the chewable ice 270) so that the material has a desired shape along a cross-section that is perpendicular to the direction of flow of the material as the material moves through the extruder head 254.

It should be understood that when the ice making screw 246 is assembled with the ice making cylinder 244, water is stored/held in a clearance space configured between the inner surface 282 of the ice making cylinder 244 and an outer surface 284 of the ice making screw 246. Additionally, the ice making cylinder inner surface 282 may include left-handed spirals 286 along a central longitudinal axis 110 of the ice making cylinder 244. The longitudinal axis 110 of the ice making cylinder 244 may be generally referred to as the cylindrical axis of the ice making cylinder 244. The ice making screw 246 may include edges 288 configured to scrape away an ice accumulation formed in the ice making zone (e.g., an interior wall or an inner surface 282 of the ice making cylinder 244 or a portion of the inner surface 282) to break the layer ice into the ice flakes for transitioning into a compaction area 252. The compaction area 252 is configured at a base of the extruder head 254 and rotation of the ice making screw 246 forces the compacted and chewable ice 270 through the extrusion apertures 255 forming cylinders or nuggets of chewable ice 270. The chewable ice 270 may be referred to as nugget ice or chewable nugget ice. The cylinders of chewable ice 270 collide with an extruder head surface 253 to shear the cylinders into smaller chewable ice nuggets referred to herein as chewable ice pellets 271. Merely by way of a non-limiting example, the extruder head surface 253 is illustrated as being angled. Alternatively, instead of angled the surface could be rounded, concave, convex, T-shaped or any other known geometry configured to shear the cylinders into smaller chewable ice pellets 271 while directing the ice pellets 271 toward the ice bin assembly 206.

To further aid in the cooling for ice production a plurality of fins 291 may be included on the external surface 245 of the ice making cylinder 244. The fins 291 are configured radially around and in direct contact with the external surface 245 of the ice making cylinder 244. The fins 291 may be constructed as a plurality of single discs having a central aperture 292 and slid over the ice making cylinder 244 to create a stacked configuration. The fins 291 may be stacked in a direction along an axis of the ice making cylinder 244 (e.g., the central longitudinal axis 110 of the ice making cylinder 244). Alternatively, the fins 291 may be cast as a single tube fin assembly also having the central aperture 292 that is configured to slide over and receive the ice making cylinder 244. The configuration of fins 291, whether comprising stacked single discs or a single cast, is illustrated in FIG. 7. Turning back to FIG. 6, another alternative fin assembly 293 including the plurality of fins 291 is illustrated. Fin assembly 293 is an alternative configuration where the fins 291 are formed on a single tube fin assembly that is split along the long axis plane to divide the single cylinder of fins into a fin assembly first half 294 and a fin assembly second half 296, the first half 294 and the second half 296 are configured to act as a clam shell to encase the ice making cylinder 244 external surface 245, thereby creating a set of continuous fins extending radially around the external surface 245.

Additionally, an insulation housing or insulation body 300 is included. The insulation body is configured to surround the plurality of fins 291, in any configuration described herein, to help maintain the ice making temperatures and prevent heat loss. The insulation body 300 may be referred to as the insulator. The insulation body 300 may define a gap between an internal or inner surface 302 of the insulation body 300 and a fin outer surface 298, which may include the outer surfaces 298 of one, some, or all of the fins 291. Alternatively, the insulation body 300 inner surface 302 may fit tightly against the fin outer surface 298 such that the fins 291 engage the inner surface 302 on opposing side of the fins 291 relative to the ice making cylinder 244, and radially outward from the ice making cylinder 244, to force the cooling air to flow across each individual fin 291. It should be understood that the insulation body 300 may include an open inlet side or inlet aperture 304 that is fluidically connected to the cold air supply through the ice maker feed duct 72. The insulation body 300 may also include a return air opening or return air aperture 306 that is fluidically connected to the ice maker return duct 82. The return air aperture 306 may also be referred to as the outlet aperture. The inlet aperture 304 and the return air aperture 306 may be formed as a single opening in the insulation body 300 as shown in FIG. 7 or as separate openings in the insulation body 300. The positions of the inlet aperture 304 and the return air aperture 306 may be swapped in FIG. 6. Additionally, a damper 308 (FIG. 13) may be included in at least one of the inlet aperture 304 and the return air aperture 306. The damper 308 may include a damper housing 310 (FIG. 13) with a damper flap 312 (FIG. 13) positioned within the housing 310 and rotatably connected to a stepper motor 314 (FIG. 13), the stepper motor 314 is configured to selectively transition between an open position to supply cold air and a closed position to seal and prevent the ice making extruder assembly 268 from receiving cold air.

Turning back to FIG. 6, merely by way of illustrating a non-limiting example, the insulation body 300 is configured to separate along an axial parting line into two separate pieces. Similar to the fin assembly 293, which is split along the long axis plane to divide the single cylinder of fins into the fin assembly first half 294 and the fin assembly second half 296, the insulation body 300 is split along the long axis plane to divide the insulation body 300 into a first insulation body half 316 and a second insulation body half 318. The first body half 316 and the second body half 318 are configured to act as a clam shell to encase the fin outer surface 298 thereby creating a closed cooling chamber around and encapsulating the continuous fins 291 extending radially around the external surface 245.

Referring to FIG. 8, the first water storage tank 222 is illustrated in phantom and/or as transparent to further illustrate the internal components, such as the level sensor 226. By way of a non-limiting example the level sensor 226 is a float sensor that measures low and high levels within the first water storage tank 222. Alternatively, the level sensor 226 may be of any known liquid level sensor, including, but not limited to light, resistive strip sensors and infrared that are configured to receive a depth measurement and send a signal back to the controller to operate an inlet water valve 234. The first water storage tank 222 may also include a sanitization element 264A to kill bacteria in the stored water, the sanitization element 264A may include but is not limited to an ultra-violet light or other such sanitizing device. A filtration element may also be used such as a water filter (not illustrated) fluidically connected to the ice maker water line 228.

Additionally, the water system may include an overflow water line 236 that extends from the top of the first water storage tank 222 down to a secondary or second water storage tank 238. The second water storage tank 238 is configured to receive and store melt water that results from the chewable ice pellets 271 melting or partially melting while being stored in the ice bin assembly 206. The second water storage tank 238 may also collect any other water resulting from the ice making process. The second water storage tank 238 may be fluidly connected to a pump 256 via a storage tank water line 258 extending from the second water storage tank 238 to the pump 256. The pump 256 further includes and/or is connected to a recycled water line 260 extending from the pump 256 and to a recycled water line inlet 262 configured on the first water storage tank 222. The second water storage tank 238, storage tank water line 258, pump 256, and recycled water line 260 may collectively form a water recycling system that collects melt water from the ice bin assembly 206 and delivers the melt water back to the first water storage tank 222. The first water storage tank 222 is fluidly connected to a refrigerator water source (e.g., a domestic water supply that is connected to the inlet water line 216 at the water supply end 218) and the water recycling system. The first water storage tank 222 is configured to selectively switch between the refrigerator water source and the water recycling system.

The second water storage tank 238 may also include a sanitization element 264B to kill bacteria in the stored water, the sanitization element may include but is not limited to an ultra-violet light or other such sanitizing device. It should be understood that anyone or a combination of filtration elements, screens, and strainers may be fluidically coupled to along the water path between the second water storage tank 238 and the first water storage tank 222 and ultimately the water inlet 240 to filter and remove any contaminants that may be in the ice making water prior to introduction into the ice making cylinder 244. Additionally, the sanitization elements 264A, 264B may also be positioned in the same flow path to remove bacteria prior to introduction into the ice making cylinder 244.

Turning to FIGS. 9-11, the ice bin assembly 206 and the ice discharge assembly 208 may include an ice chute cover 330. The ice chute cover 330 has been removed from the ice discharge assembly 208 in FIGS. 10A-11 for illustrative purposes. Additionally, the process and parts used for transferring the chewable ice 270, or more specifically the chewable ice pellets 271, to the ice bin 350 and then exiting the ice bin 350 and out the ice chute 332 will also be discussed. As illustrated the ice bin 350 is a cube housing with solid walls. However, the ice bin 350 shape is not limiting and is merely the most efficient for the space inside the door 18. It should be understood that the ice bin 350 may include perforated walls with apertures and slots configured to guide cooling air into the interior of the ice bin 350 thereby providing cooling air to the stored chewable ice 270, or more specifically the chewable ice pellets 271. Turning specifically to FIG. 9, the top of the ice maker assembly 204 includes a top cover or cap 320 positioned over the extruder head 254 and may direct the chewable ice pellets 271 toward the ice bin 350. The cap 320 may also direct any cold air coming from the ice making extruder assembly 268 through a slot and toward the ice bin 350 to help cool any stored chewable ice pellets 271. The cap 320 may be mated to a lower cap 322 positioned beneath the cap 320 surrounding the extruder head 254 with an ice landing surface 324 for catching the ice pellets 271 pushed out of the extrusion apertures 255. The ice landing surface 324 includes a downwardly sloped ramp 326 for transitioning the ice pellets 271 from the extruder head 254 sliding down the ramp 326 emptying into the ice bin 350. A pair of sensors 328 may be included at a bottom of the ramp 326, the sensors 328 may create a light curtain that sends a signal if ice pellets 271 are blocking the end of the ramp 326 indicating a possible over full ice bin 350 or the sensors 328 may be configured to send a signal to the controller if no ice pellets 271 are leaving the ice making extruder assembly 268.

Additionally, it is contemplated and merely by way of non-limiting example that the lower cap 322 may be configured to provide mounting points and support for other components of the ice maker assembly 204, such as, but not limited to supporting level sensors 226, damper stepper motor 314, and damper 308, and a junction box (not illustrated) for connecting electronic components with the controller. The lower cap 322 may also be configured to connect and support the ice maker feed duct 72 and the ice maker return duct 82 to provide the air path to the ice making extruder assembly 268, in place of in combination with the assembly frame 266 and corresponding support wall 267.

The ice bin assembly 206 is selectively removable with a latch 354 and may include the ice bin 350 positioned over and mated to a lower ice bin 352. The latch 354 is slidingly engaged with the lower ice bin 352 and configured to selectively engage a plurality of latch toggles 355 protruding from a top surface 344 of a chute plate 334. The chute plate 334 provides a base for mounting and supporting the ice maker assembly 204 and the ice bin assembly 206 on the top surface 344. A bottom surface 346 of the chute plate 334 is configured to support an auger drive motor 372 mounted to the bottom surface 346 and including an auger drive motor shaft 374 extending through the chute plate 334. The auger drive motor shaft 374 is configured to couple to an auger assembly 356, the auger assembly including an auger coupling socket 358, an ice wheel 360, bottom plate 362 and an auger arm 364. The auger coupling socket 358 is connected to the auger arm 364 and at least one ice wheel 360. The bottom plate 362 may be affixed to the bottom of the lower ice bin 352 and includes an ice ejection aperture 370. The ice ejection aperture 370 is configured to align with an ice aperture (not illustrated) configured in the bottom of the lower ice bin 352. The ice ejection aperture 370 and the ice aperture are aligned with the ice chute 332 extending through the chute plate 334 and into the ice dispensing station 2 positioned in the front of the first door 18 to provide chewable ice pellets 271 to a user by rotating the auger drive motor 372, resulting in the ice wheel 360 and the auger arm 364 rotating to break up any ice clumps and push the ice pellets 271 into the ice chute 332.

Additionally, to aid in the positioning of the ice bin 350, a lower bin alignment channel 366 (or channels) is configured on the sides of the lower ice bin 352. Corresponding projections are configured on a wall of the housing 202 and the assembly frame 266, adjacent the ice bin assembly 206. A reed switch 368 or reed switch magnet may be used to send a presence detection signal to the controller when the ice bin assembly 206 is not in place to prevent ice from being ejected into the housing 202 when the ice bin 350 is not present. It should be understood that the auger assembly 356 is a mechanism for redistributing ice and breaking clumping bonds in ice that occur due to the melting and refreezing of the ice pellets 271 during storage in the ice bin 350.

Moreover, as the ice is stored in fresh conditions, it can melt over time due to the heat gain from the external environment. Therefore, the ice bin 350 also includes a melt water drain and ice bin check valve 338. Once the melt water starts to collect at the base of the ice bin 350 the water will flow through the check valve 338 and through an ice bin drain channel housing 340 or alternatively through a channel (not illustrated) cut into the chute plate top surface 344. This melt water exits the ice bin drain channel housing 340 into the second water storage tank 238 for recycling, as previously discussed. Additionally, in some cases the melt water may be drained directly into the ice chute cover 330. The ice chute cover 330 is configured with a drain line 342 positioned at a bottom most point to allow melt water to flow naturally down. The drain line 342 may be fluidically connected to a defrost water tray configured in a machine compartment of the refrigerator 10 where the melt water may evaporate. The second water storage tank 238 is mounted to the chute plate bottom surface 346 and includes a second water storage tank cover 348 configured on the chute plate top surface 344 where the water lines 258, 260 and pump 256 are connected to move the melt water as previously discussed.

Turning to FIGS. 12A, 12B and 12C, various alternative and non-limiting auger examples are illustrated and disclosed. Specifically, FIG. 12A illustrates a “Z” shaped rod type auger arm 464 configured to be received in an auger assembly (not illustrated) similar to the auger assembly 356, discussed above. The auger arm 464 has a circular cross-section, which avoids the crushing of the chewable ice pellets 271 while rotating. This auger arm 464 has a first bottom bend 465, and a second top bend 466. The first and second bends 465, 466 provide a de-clumping of nuggets at the top & bottom side respectively. The middle part 467 of the auger arm 464 can be constructed as planar or a spiral, as illustrated. The design having a number of bending radii decides the effectiveness of the auger arm 464 to de-clump the ice. The symmetrical design of the auger arm 464 ensures de-clumping of the ice pellets 271 while the auger arm 464 rotates in a dispensing mode. It dispenses all ice pellets 271 without a bigger chunk leftover in the lower ice bin 352.

Alternatively, FIG. 12B illustrates a comb auger 564, the comb auger 564 includes a plurality of horizontal teeth 565 and a plurality of vertical teeth 566, the teeth 565, 566 extending from a plurality of radially projecting arms 567 extending from an auger arm shaft 568. The teeth 565, 566 ensure the effective de-clumping (e.g., two-clumped pellet ice 271 over three-clumped pellet ice 271) of ice pellets 271 over the period of a short time span. The number of teeth 565, 566 and their spacing decides the effectiveness of de-clumping. Less spacing leads to the breaking of the ice pellets 271 instead of breaking the bonding between them, which forms the clumps. More spacing reduces the effectiveness of de-clumping. Sharp edges may be avoided throughout the auger arm 564, otherwise, it can lead to the crushing of ice.

Additionally, a flat beater auger arm 664 is disclosed in FIG. 12C. The flat beater auger arm 664 includes a central auger arm shaft 665 with a plurality of arms 666 configured on lateral sides of the central auger shaft 665. The arms 666 are arranged in a staggered fashion with constant spacing and having a loop 667 extending around and outer periphery of the arms 666. The cross-section of the arms 666 (FIG. 12D) includes a diamond shape 668 having four corners with radii providing more de-clumping pressure with less contact surface.

In operation, the ice making water is supplied utilizing a refrigerator water supply having a standard line water pressure from the user's municipal water supply. The water supply is fluidically interconnected between the refrigerator filter water system (not illustrated) through the inlet water line 216, routed through a refrigerator door hinge 224 and extending into the first water storage tank 222, as discussed above. The inlet water line 216 includes the inlet water valve 234 to meter the volume supplied to the first water storage tank 222 based at least on the signal received from the level sensor 226. The water then flows out of the first water storage tank 222, through the ice maker water line 228 and into the ice making cylinder 244 to assume the ice making space configured between the ice making cylinder inner surface 282 and the ice making screw outer surface 284. The first water storage tank 222 may be a referred to as the water supply tank since it supplies water to the ice making cylinder 244. A constant supply of water is provided to the ice making cylinder 244 by pressure head equalization based on the level of water in the first water storage tank 222. The ice making screw 246 is coupled to the ice making drive motor 248 that drives rotation of the ice making screw 246 pushing the water up from the ice making cylinder base 242 through an ice making zone (e.g., an inner surface 282 of the ice making cylinder 244 or a portion of the inner surface 282). As the ice making screw 246 rotates and ice starts to form on the walls the screw edges 288 scrape the cylinder inner surface 282 to flake the ice crystals and push them toward the compaction area 252 where crystalized or frozen water flakes are compacted against an extruder head 254 and pushed out to make the ice cylinders before ultimately breaking into chewable ice pellets 271 from contact with the extruder head surface 253.

As discussed above, air flow around the ice making extruder assembly 268 is an essential part of the ice making process for forming the ice crystals and ice flakes on the cylinder inner surface 282. Referring now to FIG. 13, a top isometric cross-sectional view of the ice maker assembly 204 is illustrated. This view provides a detail of a cold air 114 entering the ice maker air supply inlet 104 and a return air flow 116 exiting the ice maker return air outlet 106. Cold air 114, is air below 0° C., entering through the air supply inlet 104 from the ice maker feed duct 72 and circulating around the fins 291 and flowing above and below each individual fin 291.

The insulation body 300 and the ice making cylinder 244 define an air flow channel, air flow path, air space, or air flow space 301 therebetween for circulating the cold air 114. More specifically, the insulation body 300 is disposed radially around the outer or external surface 245 of the ice making cylinder 244 such that the air flow channel, air flow path, air space, or air flow space 301 is defined between the insulation body 300 and ice making cylinder 244, radially outward from the ice making cylinder 244, and radially inward from the insulation body 300. The air flow channel, air flow path, air space, or air flow space 301 is operable or arranged to receive cooling or cooled air from a supply (e.g., the cooling system 67 via the duct assembly 70) and direct the cooling or cooled air radially around the ice making cylinder 244. The insulation body 300 further defines an inlet (e.g., inlet aperture 304) to the air flow space 301 extending inward toward the ice making cylinder 244. The insulation body 300 further defines an outlet (e.g., return air aperture 306) from the air flow space 301. extending outward from the ice making cylinder 244.

The fins 291 are disposed within the air flow space 301 such that the cooling air is configured to circulate radially around the cylinder and between adjacent fins 291, as illustrated by arrows 303. The fins 291 may be stacked along the central longitudinal axis 110 of the ice making cylinder 244 such that the fins 291 divide the air flow channel, air flow path, air space, or air flow space 301 into a plurality of air flow channels, air flow paths, air spaces, or air flow spaces 305 wherein each air flow channel, air flow path, air space, or air flow space 305 (other than the upper most and lower most air flow channel, air flow path, air space, or air flow space 305) is divided by a pair of adjacent fins 291. Each air flow channel, air flow path, air space, or air flow space 305 divided by the fins 291 may be operable or arranged to receive cooling or cooled air from a supply (e.g., the cooling system 67 via the duct assembly) and direct the cooling or cooled air radially around the ice making cylinder 244 from the inlet aperture 304 to the return air aperture 306.

Cold air 114 flow over and around the annular fins 291 will freeze the ice by convective cooling inside the ice making extruder assembly 268. Ice pellets 271 made will get dispensed from extruder head 254 and into the ice bin 350 as discussed above. Once the air flows around the annular fins 291 the air is directed into the return air outlet 106 by a divider wall or partition 118 allowing the return air flow 116 to escape through the outlet air duct 106. The fins 291 are made of a material with high thermal conductivity such as, but not limited to aluminum, steel, copper or other high thermal conductivity metal, which is important to increase the heat transfer area between the ice making cylinder 244 walls and the surrounding air.

The fins 291 are enclosed by the insulation body 300, such as, but not limited to Styrofoam or other insulative material. Heat transfer occurs primarily between the ice making cylinder 244 and the cold air 114, and not necessarily with the ambient external environment. As the cold air is in contact with the fins 291 the cooling is transferred to the ice making cylinder inner surface 282 (e.g., heat is transferred away from the ice making cylinder inner surface 282), cooling down the water inside the ice making cylinder 244, and starting a phase change in the water, which turns the water into ice layers, so the harvesting process can be started. It is important to mention that the cold air 114 to the fins 291 may be controlled by the fans 100, 102 and the damper 308.

Alternatively, a specific ice making fan (not illustrated) may be placed in one of the air ducts 72, 82 to push or pull the air flow moving more air across the individual fins 291. Any time the ice making is activated, the fans 100, 102 is turned on and the damper 308 is open, allowing the cold air to flow through each individual fin 291. Once the ice making is deactivated, the damper 308 is closed and the fans 100, 102 is turned off. That is an important measure since when the ice making is off, there should be no cold air supply to the fins and cylinder allowing the water remaining in the ice making cylinder 244 to remain liquid inside the cylinder. Once the chewable ice pellets 271 are harvested and stored in the ice bin 350, as discussed above. The ice pellets 271 are manipulated using the auger assembly 356 to redistribute the ice pellets 271 within the ice bin 350 thereby breaking up any clumps or fused ice.

While disclosed as one controller, the controller may be part of a larger control system and may be controlled by various other controllers throughout the refrigerator 10. It should therefore be understood that the controller and one or more other controllers (e.g., controller 720, controller 748, controller 794, controller 837, controller 876, etc.) can collectively be referred to as a “controller” that controls various actuators in response to signals from various sensors to control functions the refrigerator 10 or refrigerator subsystems. The controller may include a microprocessor or central processing unit (CPU) in communication with various types of computer readable storage devices or media. Computer readable storage devices or media may include volatile and nonvolatile storage in read-only memory (ROM), random-access memory (RAM), and keep-alive memory (KAM), for example. KAM is a persistent or non-volatile memory that may be used to store various operating variables while the CPU is powered down. Computer-readable storage devices or media may be implemented using any of a number of known memory devices such as PROMs (programmable read-only memory), EPROMs (electrically PROM), EEPROMs (electrically erasable PROM), flash memory, or any other electric, magnetic, optical, or combination memory devices capable of storing data, some of which represent executable instructions, used by the controller in controlling the refrigerator 10 or refrigerator subsystems.

Control logic or functions performed by the controller may be represented by flow charts or similar diagrams in one or more figures. These figures provide representative control strategies and/or logic that may be implemented using one or more processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. As such, various steps or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Although not always explicitly illustrated, one of ordinary skill in the art will recognize that one or more of the illustrated steps or functions may be repeatedly performed depending upon the particular processing strategy being used. Similarly, the order of processing is not necessarily required to achieve the features and advantages described herein but is provided for ease of illustration and description. The control logic may be implemented primarily in software executed by a microprocessor-based controller, such as controller. Of course, the control logic may be implemented in software, hardware, or a combination of software and hardware in one or more controllers depending upon the particular application. When implemented in software, the control logic may be provided in one or more computer-readable storage devices or media having stored data representing code or instructions executed by a computer to control the refrigerator 10 or its subsystems. The computer-readable storage devices or media may include one or more of a number of known physical devices which utilize electric, magnetic, and/or optical storage to keep executable instructions and associated calibration information, operating variables, and the like.

Referring now to FIGS. 14-17, an exemplary ice making system 700 is illustrated that includes both a solid ice maker 702 and a chewable ice maker 704 disposed within a shared internal compartment or shared internal space 706 defined in the door 18 of the refrigerator 10. The arrangement and positioning of the ice making system 700 within the door 18 may be substantially the same as that of the chewable ice making system 200 described in connection with FIGS. 1-13, except that the ice making system 700 further includes the solid ice maker 702 in addition to the chewable ice maker 704. Both the solid ice maker 702 and the chewable ice maker 704 are disposed and enclosed within a housing 708 having an access door, the housing and door being similar in construction and function to the housing 202 and ice maker door 212 previously described. The housing 708 defines an insulated chamber configured to maintain separate cooling zones for the solid ice maker 702 and the chewable ice maker 704 while minimizing heat transfer to adjacent refrigerator compartments 12.

The solid ice maker 702 may be in the form of a twist-tray ice maker, that includes a twist tray 711 that is configured received liquid water within recesses or cavities for freezing while the recesses are facing upward. The twist tray 711 is also configured to rotate about an axis once the liquid water freezes into ice such that the cavities face downward to dispense solid or cube-shaped ice. The twist tray 711 is mounted on a rotational support and is operatively coupled to a motor 722 that is in communication with a controller 720. The twist tray 711 may be configured to rotate approximately 180 degrees between a fill position and a dispense position. In the fill position, the twist tray 711 is oriented to receive water from a water supply line 724 through an inlet valve controlled by the controller 720. The cooling system 67 directs cooling or cold air through a first duct 712 from the evaporator 69 to the solid ice maker 702 to freeze the water into solid ice cubes. Therefore, the first duct 712 is in fluid communication with the shared internal space 706, or at least the portion of the shared internal space 706 that houses the solid ice maker 702.

Once the cubes are formed, the controller 720 actuates the motor 722 to rotate the twist tray 711 to the dispense position, thereby inverting the twist tray 711 so that the formed ice cubes are released. The solid ice cubes fall by gravity into the ice bin assembly 206 (e.g., FIG. 14), or alternatively, directly into a dispenser 730 (e.g., FIG. 15), depending upon the system configuration. The dispenser 730 may correspond to or may include ice chute 332. The motor 722 then returns the twist tray 711 to the fill position to receive water for the next ice-making cycle. This process provides an automatic harvest and refill sequence that ensures continuous cube ice production with minimal mechanical complexity. The twist tray 711 configuration may, in some embodiments, utilize a six-cavity tray arrangement to optimize space and freezing efficiency for integration within the door assembly. However, any tray with any appropriate number of cavities may be utilized. The solid ice maker 702 may include one tray 711 (e.g., FIG. 14) or multiple trays 711 (e.g., FIG. 15).

Adjacent to the solid ice maker 702, the chewable ice maker 704 is disposed within the shared internal space 706. The chewable ice maker 704 may have substantially the same construction and components as the ice maker assembly 204 previously described. Specifically, the chewable ice maker 704 includes the ice making extruder assembly 268 comprising the ice making cylinder 244, the rotating auger or ice making screw 246, and the extruder head 254 defining the plurality of extrusion apertures 255. During operation, water is introduced into the ice making cylinder 244 where it is cooled by cooling or cold air from the second duct 714. More specifically, the cooling system 67 directs cooling or cold air through the second duct 714 from the evaporator 69 to the chewable ice maker 704. Therefore, the second duct 714 is in fluid communication with the shared internal space 706, or at least the portion of the shared internal space 706 that houses the chewable ice maker 704.

The ice making screw 246, driven by a drive motor 248, scrapes ice that forms along the interior wall of the ice making cylinder 244 and compacts it toward the extruder head 254. The compacted ice is extruded through the extrusion apertures 255, forming chewable ice rods or nuggets that are sheared into smaller chewable ice pellets 271 by the extruder head surface 253 of the extruder head 254. The pellets are then directed either to the shared ice bin assembly 206 via a chute 715, as shown in FIG. 14, or directly to the chute 332 and dispenser 730 for on-demand dispensing, as shown in FIG. 15. The first duct 712 and the second duct 714 may be connected to the cooling system 67 and the evaporator 69 via the ice maker feed duct 72. The first duct 712 and the second duct 714 may be considered to part of the cooling system 67. The overall construction of the chewable ice maker 704 thereby enables production of soft, chewable nugget ice within the same compartment as the solid ice maker without requiring a separate water system or independent evaporator. The dispenser 730 is at least partially positioned on exterior to the door 18 (e.g., FIG. 16). The dispenser 730 is in communication with the shared internal space 706. The dispenser 730 is operable to dispense the both the solid ice and the chewable ice from the shared internal space 706.

The cooling system 67 is in fluid communication with both the solid ice maker 702 and the chewable ice maker 704, and supplies cold air at different temperatures (e.g., a first temperature and a second temperature) through the duct assembly 70. The duct assembly 70 is connected to the first duct 712 and the second duct 714, is fluidly connected to the cooling system 67, and terminates at the housing 708 of the ice making system 700. The first duct 712 includes a first damper 716 and the second duct 714 includes a second damper 718 that are disposed within the first duct 712 and second duct 714, respectively. The first damper 716 and the second damper 718 are selectively controlled by the controller 720.

When the solid ice maker 702 is activated (e.g., in response to a command to produce solid ice via a user interface 732), the controller 720 opens the first damper 716 to permit the flow of colder air, having a first temperature that is less than the freezing point of water, to the solid ice maker 702, while closing the second damper 718 to restrict airflow to the chewable ice maker 704. Conversely, when the chewable ice maker 704 is in operation (e.g., in response to a command to produce chewable ice via the user interface 732), the controller 720 opens the second damper 718 to direct cooling air at a second, slightly higher temperature to the chewable ice maker 704, while closing the first damper 716. The second temperature may be slightly greater than the freezing point of water. Therefore, the first temperature (e.g., the temperature of the air being directed to the solid ice maker 702) is less than the second temperature (e.g., the temperature of the air being directed to the chewable ice maker 704). The first duct 712 and second duct 714 may each be thermally insulated to maintain the desired air temperature and minimize cross-thermal interaction between the two ice-making zones. The system may also operate to simultaneously direct cooling air to both the solid ice maker 702 and the chewable ice maker 704. For example, the dampers 716, 718 may be driven by stepper motors, solenoids, or other electronically controlled actuators 719 capable of variable positioning to fine-tune the airflow and temperature balance between the two ice makers.

In the embodiment of FIG. 14, the solid ice maker 702 and chewable ice maker 704 both deliver ice into the shared ice bin assembly 206 disposed beneath the ice makers within the shared compartment 706. The ice bin assembly 206 is similar in structure to the bin described in connection with FIGS. 9-11 and is configured to store and agitate ice from the solid ice maker 702 and chewable ice maker 704 to prevent clumping. The ice bin assembly 206 may include the auger arm 364 driven by the auger motor 372 for redistributing the ice and breaking apart fused pieces. Both solid and chewable ice collected in the ice bin assembly 206 may subsequently be delivered from the ice bin assembly 206, through the ice chute 332, and to the dispenser 730 on the exterior of the door 18, as shown in FIG. 16. In this configuration, the solid and chewable ice types may be stored together within the ice bin assembly 206, or only one type of ice (e.g., solid ice or chewable ice) may be stored in the ice bin assembly 206 depending on a selected configuration. The ice is selectively dispensed through engagement with a user interface 732, which allows a user to select between cube ice, chewable or nugget ice, or crushed ice and to dispense the selected ice.

In the alternative configuration shown in FIG. 15, both the solid and chewable ice makers are arranged to dispense ice directly and independently to the dispenser 730 without storage. This “on-demand” arrangement eliminates melt water accumulation and allows the refrigerator to produce ice only when requested. The user interface 732 communicates with the controller 720 to initiate the production of the desired ice type. The controller 720 then actuates the corresponding ice maker and damper settings as described above to deliver freshly produced ice through the ice chute 332.

As shown in FIG. 17, the ice making system 700 may further include an ice crusher assembly 736 positioned along the ice chute 332 or at the outlet of the ice bin assembly 206 along the lower ice bin 352. The ice crusher 736 may include a plurality of crushing blades 738 having teeth 741 that rotate to fracture either solid cube ice or chewable ice pellets into smaller crushed pieces as the ice is directed from the ice bin assembly 206 to the dispenser 730. The operation of the crusher assembly 736 is controlled by the controller 720 in response to the user selecting a “crushed ice” option from the interface 732. The controller 720 thereby coordinates all ice production and dispensing operations, including the activation of the motors 722 and 248, the dampers 716 and 718, and the crusher 736, to deliver the selected ice type efficiently. The blades 738 may rotate about the same axis as the auger 364. Rotation of the blades 738 may be activated by an electric motor such as auger motor 372. The motor may be separate from the auger motor 372 or may be the auger motor 372. In the event the auger 364 and blades 738 are both rotated by the auger motor 372, a clutch may selectively connect the blades 738 to the auger motor 372 to facilitate or prevent crushing the ice. The motor (e.g., auger motor 372) and clutch may be in communication with and controlled by the controller 720.

The cooling air for both the solid and chewable ice makers is supplied from the evaporator housing 64 through the duct assembly 70. The cooling system 67 thereby maintains distinct air streams for the solid and chewable ice makers, one below freezing for the cube ice maker 702 and one slightly above freezing for the chewable ice maker 704. The use of separate ducts and dampers allows for efficient thermal zoning while still utilizing a single evaporator system, reducing both energy consumption and overall system complexity.

The user interface 732 may include touch-sensitive controls, mechanical buttons, or a digital display configured to communicate with the controller 720. Through this interface, a user can select between ice types (solid, chewable, or crushed), monitor ice-making status, and initiate cleaning or defrost cycles. The controller 720 may also be programmed to optimize operation based on ice demand, ambient temperature, or door usage frequency, thereby improving energy efficiency and performance stability.

In use, the ice making system 700 enables a refrigerator appliance to produce multiple types of ice within a single in-door compartment. The integration of the solid ice maker 702 and chewable ice maker 704 within the shared housing 708 allows for efficient use of space while maintaining distinct temperature environments for different ice textures. The shared duct assembly 70, combined with selectively operated dampers, provides precise thermal control between the two ice-making zones. The ice crusher 736 further enhances functionality by allowing production of crushed ice from either source. Overall, the design provides consumers with the flexibility to choose between cube ice, chewable ice, or crushed ice directly from the door, improves usability through the unified interface, and reduces system complexity by leveraging shared cooling and control components.

Referring now to FIGS. 18-20, an ice making system 740 for the refrigerator 10 is shown that includes both a solid ice maker 742 and a chewable ice maker 744. The solid ice maker 742 is also referred to as a cube ice maker, and the chewable ice maker 744 is also referred to as a nugget ice maker. The ice making system 740 provides two independent ice-making assemblies located in different regions of the refrigerator appliance to improve capacity, accessibility, and user flexibility.

The solid ice maker 742 is disposed in the door 18 of the refrigerator appliance. The solid ice maker 742 may comprise a twist tray ice maker that rotates about an axis to form and dispense cube-shaped ice. A motor 746 is in communication with a controller 748. The controller 748 actuates the motor 746 to rotate the tray 743 through approximately 180 degrees between a fill position and a dispense position. In the fill position, water is received from a water supply line into cavities defined within the twist tray 743. Cold air from the cooling system 67 is directed to the solid ice maker 742 from the evaporator 69 through a duct (e.g., ice maker feed duct 72) that forms part of the duct assembly 70. The water freezes to form solid cube ice pieces. After freezing, the controller 748 actuates the motor 746 to rotate the tray 743 to the dispense position, causing the ice cubes to fall by gravity into a cube ice bin 754 positioned in the door 18 for later dispensing through a dispenser 756. Alternatively, the ice bin 754 may be omitted and the ice cubes may fall directly from the tray 743 to the dispenser 753. The dispenser 756 is disposed along an exterior of the door 18. The dispenser may comprise or may include an ice chute. Once the cubes are dispensed, the tray 743 returns to the fill position to receive additional water for freezing. This sequence may be repeated automatically to maintain an available supply of cube ice.

The chewable ice maker 744 is disposed within the refrigerator compartment 12. The chewable ice maker 744 has the same construction and elements as the ice maker assembly 204 described previously. However, the melt water reservoir (e.g., the second water storage tank 238) may be repositioned so that is directly below the ice bin assembly 206. The chewable ice maker 744 includes the ice making cylinder 244, the rotating ice making screw 246, and the extruder head 254 having extrusion apertures 255 through which compressed ice is extruded to form chewable or nugget ice. The ice making screw 246 is driven by the drive motor 248 that is controlled by the controller 748. The extruded nugget ice is delivered into the ice bin assembly 206 disposed beneath the chewable ice maker 744. The ice bin assembly 206 may store the nugget ice for later dispensing. The ice bin assembly 206 may or may not be connected to the dispenser 756. If the ice bin assembly 206 is connected to the dispenser 756, the chewable ice may be dispensed via the dispenser 756 through a chute, similar to ice chute 332. If the ice bin assembly 206 is not connected to the dispenser 756, a user may directly access the bin assembly within the refrigerator compartment 12 to obtain the chewable ice.

The cooling system 67 supplies chilled air to both the solid ice maker 742 and the chewable ice maker 744. The cooling air is distributed through the duct assembly 70, which includes the ice maker feed duct 72, ice maker return duct 82, and multiple branching ducts 758. The ice maker feed duct 72 and ice maker return duct 82 operate to deliver air from the evaporator 69 of the cooling system 67 to the solid ice maker 742 and return air from the solid ice maker 742 to the evaporator 69 of the cooling system 67, respectively. A first of the branching ducts 758A and a second of the branching ducts 758B operate to deliver air from the evaporator 69 of the cooling system 67 to the chewable ice maker 744 and return air from the chewable ice maker 744 to the evaporator 69 of the cooling system 67, respectively. The first of the branching ducts 758A and the second of the branching ducts 758B may be considered to be part of the cooling system 67.

The ice maker feed duct 72 and the first of the branching ducts 758A may each include a corresponding damper 760, 762 to regulate airflow to the associated ice maker. The dampers 760 and 762 are positioned within the duct assembly 70 and are selectively controlled by the controller 748. When cube ice is required, the controller 748 opens damper 760 to allow cold air to flow to the solid ice maker 742 and closes damper 762. When chewable ice is required, the controller 748 closes damper 760 and opens damper 762 to direct airflow through the branching duct 758 leading to the chewable ice maker 744. The duct arrangement thereby enables independent temperature control for each ice-making region while using the same cooling system 67. The system may also operate to simultaneously direct cooling air to both the solid ice maker 742 and the chewable ice maker 744. For example, the dampers 760, 762 may be driven by stepper motors, solenoids, or other electronically controlled actuators 761 capable of variable positioning to fine-tune the airflow and temperature balance between the two ice makers. More specifically, the solid ice maker 742 may be maintained at a temperature that is slightly less than the freezing point of water while the chewable ice maker 744 may be maintained at a temperature that is slightly greater than the freezing point of water.

As shown in FIG. 19, the chewable ice maker 744 is adjacent to the ice bin assembly 206 inside the refrigerator compartment 12. Beneath the ice bin assembly 206, a melt water reservoir 764 is provided to collect melt water from the stored nugget ice. The reservoir 764 is in fluid communication with a return line 766 that may direct the collected water to the solid ice maker 742 for reuse during the next freezing cycle, thereby improving water efficiency. A pump 765 may be configured to direct the melt water from the melt water reservoir 764 to the solid ice maker 742 via the return line 766. The pump 765 may be in communication with and controlled by the controller 748. For example, the controller 748 may operate the pump 765 subsequent to operating the motor 746 to empty the tray 743 or in response to receiving a signal from a level sensor in the melt water reservoir 764 that indicates that that water level exceeds a threshold. The water supply for the system may be connected to a household water line through a consumer connection.

The controller 748 manages operation of the solid and chewable ice makers as well as the dampers 760 and 762. The controller 748 is in communication with a user interface 774 located on an exterior surface of the door 18 or near the dispenser 756. The user interface 774 allows a user to select an ice type and initiate dispensing. The available options may include cube ice, chewable or nugget ice, or in certain embodiments crushed ice if the ice bin assembly 206 includes a crusher mechanism of the type previously described. When the user selects solid cube ice, the controller 748 operates the associated damper 760 (e.g., opens the damper 760) to produce the solid ice and operates the twist tray 743 to dispense the solid ice from the dispenser 756. When the user selects chewable ice, the controller 748 operates the associated damper 762 (e.g., opens the damper 762) to produce the chewable ice and operates the auger arm 364 to deliver chewable ice from the refrigerator compartment 12 to the dispenser 756. In embodiments where the chewable ice maker 744 is not connected to the dispenser 756 the auger arm 364 may be omitted.

The spatial separation of the two ice makers provides several functional advantages. Locating the cube ice maker 742 in the door 18 increases dispenser responsiveness and allows direct delivery of cube ice without opening the main refrigerator compartment 12. Locating the chewable ice maker 744 in the refrigerator compartment 12 increases bin capacity and enhances accessibility for cleaning and service. The arrangement also enables improved temperature control and noise isolation between the two ice-making processes. The branching duct configuration 758 permits simultaneous thermal management from a single cooling system 67 while maintaining distinct operational zones. Reuse of melt water through the reservoir 764 reduces overall water consumption. The inclusion of separate dampers 760 and 762 further increases energy efficiency by directing air only to the ice maker that is active at a given time.

In summary, the ice making system 740 provides a dual-ice-type configuration with the solid cube ice maker 742 in the door 18 and the chewable nugget ice maker 744 in the refrigerator compartment 12. The shared cooling system 67, duct assembly 70 with branching ducts 758, and controlled dampers 760 and 762 permit precise thermal regulation. The controller 748 and user interface 774 coordinate ice production and dispensing functions. The system delivers enhanced usability, higher bin capacity, and improved consumer choice between solid and chewable ice types while maintaining a compact and energy-efficient design.

Referring now to FIGS. 21-23, an ice making system 780 for an alternative configuration of the refrigerator 10 is illustrated. The ice making system 780 includes both a solid ice maker 782 and a chewable ice maker 784. The solid ice maker 782 is also referred to as a cube ice maker, and the chewable ice maker 784 is also referred to as a nugget ice maker. The two ice makers 782 and 784 are housed in separate drawers 786 and 788, respectively. The drawers are arranged in a vertical stack and are separated by a mullion 790. Each drawer defines an isolated thermal zone optimized for its corresponding ice type. The drawers are positioned between the refrigerator compartment 12 and the freezer compartment 24 vertically so that each can receive cooling air from the cooling system 67 while maintaining distinct temperatures for the respective ice types.

The solid ice maker 782 may comprise a twist-tray mechanism designed to rotate about an axis to release formed cube ice. A motor 792 is in communication with a controller 794. The controller 794 actuates the motor 792 to rotate the twist tray through approximately one hundred eighty degrees between a fill position and a dispense position. In the fill position, the tray receives water from a water supply line. Air from the cooling system 67 is directed to the solid ice maker 782 through a dedicated inlet duct to freeze the water into solid cubes. Once the cubes are formed, the controller 794 actuates the motor 792 to rotate the tray to the dispense position. The formed cubes fall by gravity into a solid or cube ice bin 800 within the drawer 786. After dispensing, the tray returns to the fill position to begin another cycle. The solid ice bin 800 may be insulated and positioned at a temperature slightly below the freezing point of water to keep the cubes hard and prevent partial melting or clumping.

The chewable ice maker 784 has the same construction and elements as the ice maker assembly 204 previously described. The chewable ice maker 784 includes the ice making cylinder 244, the rotating ice making screw 246, and the extruder head 254 having extrusion apertures 255 through which compressed ice is extruded to form chewable or nugget ice. The ice making screw 246 is driven by the drive motor 248 that is controlled by the controller 794. The extruded chewable ice drops into a chewable or nugget ice bin 802 located within the drawer 788. A hood or chute 803 may direct the chewable ice from the extruder head 254 to the nugget ice bin 802. The temperature within drawer 788 is maintained slightly above the freezing point of water to preserve the soft, chewable texture of the nugget ice and to prevent the pellets from fusing together.

The cooling system 67 is in fluid communication with both the solid and chewable ice makers. The cooling air is supplied through an air delivery network that includes separate inlet ducts 806 and 808 that deliver air to the ice makers and return ducts 810 and 812 that return air to the evaporator 69 of the cooling system 67 from the ice makers. The first set of ducts 806 and 810 provides cooling air to the solid ice maker 782 from the evaporator 69 of the cooling system 67 and returns air from the solid ice maker 782 to the evaporator 69 of the cooling system 67. The second set of ducts 808 and 812 provides cooling air from the evaporator 69 of the cooling system 67 to the chewable ice maker 784 and returns air from the chewable ice maker 784 to the evaporator 69 of the cooling system 67. The ducts maintain dedicated air paths for each drawer to establish the required temperature gradient. Some embodiments may include dampers that may be disposed within the inlet ducts 806, 808 to regulate airflow to the solid ice maker 782 and the chewable ice maker 784. In embodiments that include such dampers, the dampers may be electronically controlled by the controller 794. The controller 794 may selectively open and close such dampers to deliver cooling air at appropriate flow rates and temperatures to each drawer. The solid ice maker 782 operates at a temperature slightly below freezing, and the chewable ice maker 784 operates at a temperature slightly above freezing. This temperature separation is maintained by the mullion 790, which provides a thermal barrier between the drawers 786 and 788 while allowing the structure to remain compact and energy efficient.

A user interface may communicate with the controller 794. The user interface allows the user to select the desired ice type (e.g., solid ice or chewable ice) and to initiate production of the ice. The controller 794 coordinates the operation of both ice makers and the dampers. The dampers may be driven by stepper motors, solenoids, or other electronically controlled actuators capable of variable positioning to fine-tune the airflow and temperature balance between the two ice makers.

The return ducts 810 and 812 convey the warmed air back to the evaporator 69 of the cooling system 67 for recirculation. The chewable ice maker 784 may be partially disposed within the freezer compartment 24 to facilitate freezing water. The solid ice side of the drawer assembly is positioned closer to the freezer air outlet, maintaining a lower temperature, while the nugget ice side receives moderated air to remain above freezing. This configuration creates two controlled thermal zones, a first zone for the nugget/chewable ice at above-freezing temperature, and a second zone for the cube/solid ice at slightly below-freezing temperature. An optional melt water tank 813 may be configured to collect the melt water within the nugget ice bin 802. The melt water may then be recirculated back to the solid ice maker 782 or the chewable ice maker 784 via a pump and conduits extending from the melt water tank 813 to the solid ice maker 782 or the chewable ice maker 784 so that the melt water may be converted back to either solid or chewable ice.

The described arrangement offers several benefits. The use of dedicated drawers enables easy access to both ice types without opening the main freezer or refrigerator doors. The separate ducts and dampers provide precise temperature control for each ice-making zone, ensuring that nugget ice remains soft and cube ice remains solid. The dedicated mullion 790 maintains thermal separation and prevents cross-temperature effects. The design eliminates the need for a water recirculation system in the nugget ice maker, reducing component count and maintenance. By locating the drawers between the freezer compartment 24 and refrigerator compartment 12, the design efficiently uses space and takes advantage of the natural thermal gradient within the appliance. Users gain convenient access, enhanced ice-type flexibility, and improved performance stability, while the appliance benefits from optimized energy usage and compact construction.

In summary, the ice making system 780 includes a cube and/or solid ice maker 782 and a nugget and/or chewable ice maker 784 positioned in separate drawers 786 and 788 divided by a mullion 790. Each ice maker receives cooling air from the cooling system 67 through dedicated inlet and return ducts, which may include dampers to control the cooling air flow to each of the separate drawers 786 and 788. The drawers are located between the refrigerator compartment 12 and the freezer compartment 24, maintaining distinct temperature zones suitable for their respective ice types. The controller 794 and a user interface coordinate system operation, providing users with ready access to both solid and chewable ice from a single integrated appliance.

Referring now to FIGS. 24 and 25, an alternative configuration of a refrigerator appliance 801 is illustrated as a side-by-side type refrigerator having a freezer compartment 805 and a refrigerator compartment 807 separated by a vertically extending mullion 818. It is understood, however, that this disclosure could apply to any type of refrigerator, such as a French-Door Bottom Mount type (e.g., FIG. 1).

The refrigerator appliance 801 includes an ice making system 816 configured to produce and store chewable ice, also referred to as nugget ice. The ice making system 816 is arranged so that a chewable ice maker 820 is disposed within the freezer compartment 805, and an ice storage bin 822 is disposed within the refrigerator compartment 807. The arrangement allows ice formation in a low-temperature environment that is below the freezing temperature of water and ice storage in a higher-temperature environment that is slightly above the freezing point of water, thereby preserving the chewable texture of the ice.

The chewable ice maker 820 has the same construction and elements as the ice maker assembly 204 previously described. The chewable ice maker 820 includes an ice making cylinder 244, an ice making screw 246, and an extruder head 254 configured with extrusion apertures 255 to compact and form chewable ice pellets. A drive motor 248 is operably connected to the ice making screw 246 to rotate the auger within the ice making cylinder 244, thereby scraping ice from the inner wall of the cylinder and pushing the compacted ice toward the extruder head 254. Cooling air from the cooling system 67 is directed around the ice making cylinder 244 to promote freezing of water and to form chewable ice pellets that are discharged through the extruder head 254.

A water reservoir 824 is disposed within the refrigerator compartment 807. The water reservoir 824 provides a supply of water to the chewable ice maker 820. A water conduit 826 extends through the mullion 818 to fluidly connect the water reservoir 824 to the chewable ice maker 820. The water conduit 826 delivers water from the reservoir 824 to the ice maker 820 during an ice-making cycle. The water conduit 826 may be thermally insulated and sealed to prevent freezing of water as it passes through the mullion 818. The water reservoir 824 may also include a sanitization element such as an ultraviolet light or a filtration unit to maintain water purity and to prevent microbial growth within the reservoir. Water may be directed to the water reservoir 824 from a source (e.g., a connection to a domestic water supply) via a supply line 819. The water supply line 819 may be positioned within the mullion 818.

The chewable ice maker 820 produces chewable ice pellets that are transferred from the freezer compartment 805 to the refrigerator compartment 807 through an ice conduit 828. The ice conduit 828 may be a chute that is angled downward toward the storage bin 822 such that the ice is directed from the extruder head 254 of chewable ice maker 820 to the storage bin 822 via gravity. The ice conduit 828 extends through the mullion 818 to provide a passage between the chewable ice maker 820 and the ice storage bin 822. The ice conduit 828 may include an insulated wall to minimize warming of the ice during transfer. The ice conduit 828 may also include a chute liner or auger mechanism to aid movement of the ice pellets 271 through the mullion. The ice conduit 828 terminates above the ice storage bin 822 to discharge the ice pellets 271 directly into the bin 822.

The ice storage bin 822 is positioned within the refrigerator compartment 807 and configured to receive and store the chewable ice pellets. The refrigerator compartment 807 maintains a temperature slightly above the freezing point of water so that the ice stored within the bin 822 remains soft and chewable without fully melting. The ice storage bin 822 may include an auger arm or agitator (e.g., auger arm 364) that periodically rotates to redistribute the chewable ice pellets and prevent clumping or fusing. Melt water resulting from the stored ice may be collected in a melt water tank 832 disposed beneath the ice storage bin 822. The melt water tank 832 may be fluidly connected to the water reservoir 824 through a recycled water line 834 and a pump 836 to allow the melt water to be recirculated and reused by the ice maker 820. The pump 836 may be controlled by a controller 837 to transfer melt water when a predetermined level is detected within the melt water tank 832. The predetermined level of melt water that triggers operation of the pump 836 may be detected by a water level sensor 839, such as a float senor, which may be disposed within the melt water tank 832.

In some embodiments, the ice storage bin 822 may be fluidly connected to a dispenser assembly positioned within or on a door of the refrigerator appliance 801. The dispenser assembly may include a chute and actuator configured to dispense chewable ice pellets to a user. Although the dispenser assembly is not shown in FIGS. 24-25, it may be similar in construction and function to the dispenser 730 or dispenser 756 described previously. The dispenser assembly may be operably coupled to the controller and a user interface 841 to permit selection and dispensing of chewable ice on demand.

During operation, the controller 837 activates the ice making cycle by supplying water from the water reservoir 824 through the water conduit 826 to the chewable ice maker 820. A cooling system 867 provides cold air to the ice making cylinder 244 via conduit 838, enabling the formation of ice flakes that are compacted into chewable ice pellets by the ice making screw 246 and extruder head 254. The cooling system 867 may include an evaporator and may have the same configuration as cooling system 67. The chewable ice pellets are discharged into the ice conduit 828 and conveyed through the mullion 818 into the ice storage bin 822. The refrigerator compartment 807 maintains the stored chewable ice pellets at a temperature slightly above freezing to preserve their soft texture while minimizing melt. Melt water collected in the melt water tank 832 may be pumped back to the water reservoir 824 for reuse, improving efficiency and reducing water consumption.

The described arrangement provides multiple advantages. Positioning the chewable ice maker 820 in the freezer compartment 805 improves ice-making efficiency and production rate by utilizing the colder air temperature. Locating the ice storage bin 822 in the refrigerator compartment 807 increases accessibility to stored chewable ice while maintaining the ideal storage temperature for soft ice. The placement of both the water conduit 826 and the ice conduit 828 through the mullion 818 provides a compact and efficient connection between the compartments without reducing usable storage space. The separation of the ice-making and ice-storing zones also improves thermal management, reduces frost formation, and enhances the energy performance of the appliance.

FIGS. 26-29 illustrate an alternative configuration of the lower ice bin 352. The lower ice bin 352 defines two regions: an upper ice storage zone 853 positioned above the bottom plate 362, and a dispensing zone 855 disposed below the bottom plate 362. The bottom plate 362 is positioned within the lower ice bin 352 at an angle that slopes downward toward the ice dispensing zone 855 where the ice wheel 360 is located. The ice wheel 360 is positioned below the bottom plate 362 and above a bottom surface or floor 857 of the lower ice bin 352 within the dispensing zone 855. The angled orientation of the bottom plate 362 directs ice toward the ejection aperture 370 and into the dispensing zone 855 via gravity, which facilitates consistent ice movement.

The ice wheel 360 includes a plurality of sweep blades 859 configured to rotate within the dispensing zone 855. The sweep blades 859 drive the chewable ice toward a dispensing opening 861 that is in communication with the chute 332 in order to dispense the ice from the chute 332. A drain hole 863 is defined in the floor 857 of the lower ice bin 352. The drain hole 863 provides fluid communication to a water recirculation system, allowing melt water to be removed from the dispensing zone 855 and directed to a melt water tank (e.g., a second water storage tank 238) of a water management system. During operation, the sweep blades 859 also guide the ice toward the ice chute 332 via the dispensing opening 861.

The floor 857 of the lower ice bin 352 is angled toward the drain hole 863 and away from the dispensing opening 861. The floor 857 also defines a network of grooves 852 that channel melt water toward the drain hole 863. The grooves 852 permit melt water to flow toward the drain hole 863 during melt or defrost cycles, thereby reducing the risk of overflow. The grooves 852 may include radially extending grooves 865 that extend about a center of the floor 857 and linear extending interconnecting grooves 869 that interconnect the radially extending grooves 865. Each radially extending groove 865 may be concentric to the other radially extending grooves 865. Melt water entering the drain hole passes through the check valve 338 and is directed to the second water storage tank 238, as previously described, which prevents backflow and leakage when the ice bin 352 is removed.

The bottom plate 362 separates the upper ice storage zone from the lower dispensing zone. The floor 857 of the lower bin 352 serves as a base for the ice wheel 360 and auger arm 364. The auger arm 364 is connected to the auger drive motor and rotates within the storage zone 853 to break up clumps and move ice toward the dispensing zone 855. The dispensing opening 861 that is connected to the ice chute 332 is positioned on an opposing side of the floor 857 and upward from the drain hole 863 due to the slope of the floor 857, ensuring that ice and water are separated before dispensing (e.g., ice is directed toward the dispensing opening 861 via the ice wheel 360 while the melt water is directed toward the drain hole 863 via the grooves 852).

The lower ice bin 352 includes a series of seals. These include a top auger seal 856 positioned within the storage zone 853 and secondary auger seals 860 positioned around the shaft of the auger arm 364 within the dispensing zone 855. The secondary auger seals 860 may also engage the bottom plate 362 and the ice wheel 360. Together, these seals prevent melt water leakage around the rotating interfaces of the auger arm 364 (e.g., the interfaces between the auger arm 364 and the lower ice bin 352, the bottom plate 362, and the ice wheel 360). A collar 862 is molded in the base plate to act as an additional barrier. The joint between the bottom plate 362 and the lower bin 352, which may be made from plastic, is sealed with a mounting gasket 864, which is compressed between surfaces to restrict water flow through the interface. These combined sealing systems prevent water leaks into the ice chute or exterior surfaces, maintaining proper containment and water routing.

The configuration further prevents overflow by dividing the lower ice bin 352 into distinct water-management zones. Melt water from the storage zone 853 flows across the angled bottom plate 362 into the dispensing zone 855 and is then directed to the drain hole 863 for reuse in the recirculation system. The ice ejection aperture 370 and the dispensing opening 861 are vertical offset from each other so that melt water cannot flow from the ice storage zone 853 directly into the dispensing opening 861 and out the chute 332. The offset configuration further facilitates that water flowing from the ice storage zone 853 into the dispensing zone 855 is directed onto the angled floor 857 and to the drain hole 863. The combination of slope, grooves, and seals ensures that only ice is conveyed to the dispensing opening 861 while melt water is directed to the melt water tank (e.g., the second water storage tank 238) via the drain hole 863.

Benefits of this configuration include improved water drainage, prevention of leakage through the auger arm 364, and elimination of water leakage through the chute 332. The angled floor 857 and grooves 852 promote controlled water flow, while the sealing system ensures durable leak prevention under varying temperature and vibration conditions. This enhances appliance usability, minimizes maintenance, and extends service life by preventing internal corrosion or electrical damage from moisture exposure.

FIGS. 30-32 illustrate the melt water tank (e.g., the second water storage tank 238) and its integration with the chute plate 334. The second water storage tank 238 is mounted to the underside of the chute plate 334 and is positioned to collect melt water from the drain hole 863 of the ice bin 352. The second water storage tank 238 may be formed integrally with or attached to the ice chute cover 330, which also encloses and protects the drive motor 372.

The second water storage tank 238 includes a lid 866. The lid 866 may be secured to a lower side of the chute plate 334. The lid 866 has one or more downwardly extending protrusions 871 having walls 868. These protrusions 871 extend into the cavity of the second water storage tank 238 and the walls 868 act as splash barriers. The walls 868 prevent melt water from splashing out of the second water storage tank 238 when the refrigerator door is opened or closed, maintaining cleanliness and preventing moisture exposure to nearby components. A portion of the second water storage tank 238 is illustrated in phantom in FIG. 30.

An overflow port 870 is defined as a notch or cutout along the upper perimeter of the tank housing. The overflow port 870 provides a controlled overflow path to prevent overfilling. Melt water exceeding a predefined level flows through the overflow port 870 into an adjacent drain passage, reducing the risk of water accumulation or leakage within the refrigerator door.

A level sensor 872 is positioned within the second water storage tank 238 and is located within one of the protrusions 871 between the corresponding walls 868. The placement of the level sensor 872 within the internal wall structure stabilizes water flow near the level sensor 872, reducing measurement errors from splashing or turbulence. The level sensor 872 communicates with a system controller (e.g., controller 876) to trigger operation of a pump (e.g., pump 256) when the melt water tank (e.g., the second water storage tank 238) reaches a predetermined fill level.

The chute plate 334 supports the second water storage tank 238, the drive motor 372, and associated electrical and plumbing connections. The combination of integrated tank and cover simplifies assembly and improves space efficiency. The melt water tank lid 866 design provides resistance to water displacement during vibration or door motion, ensuring consistent liquid containment. The benefits include splash control, accurate water level sensing, and protection of nearby electronic components. The integrated tank configuration enhances system reliability by minimizing external hoses and fittings, reducing potential leak points.

FIG. 33 illustrates a water management system 874 for the chewable ice maker. The system interconnects the ice maker assembly 204, the first water storage tank 222, the second water storage tank 238 (melt water tank), and the ice bin assembly 206. Water flows between these components to provide efficient recirculation and reuse of melt water. The pump 256 draws water from the second water storage tank 238 through the storage tank water line 258 and delivers it through the recycled water line 260 back to the first water storage tank 222. The check valve 338 located below the ice bin assembly 206 prevents backflow and ensures proper drainage from the ice bin assembly 206 to the second water storage tank 238 via a drain line or channel (e.g., drain channel housing 340).

During operation, melt water formed in the ice bin assembly 206 drains through the check valve 338 into the second water storage tank 238. The first water storage tank 222 serves as the main supply for the ice making cylinder 244, while the second water storage tank 238 functions as a reservoir for reclaiming melt water. The level sensor 226 in the first water storage tank 222 and the level sensor 872 in the second water storage tank 238 send signals to a controller 876. The controller 876 operates the pump 256 based on these sensor inputs. When the second water storage tank 238 reaches a defined fill level, the controller 876 activates the pump 256 to transfer water from the second water storage tank 238 to the first water storage tank 222. The controller 876 stops the pump when the first water storage tank 222 becomes full or when a timeout threshold is reached to prevent overfilling.

The controller 876 may also coordinate ice production cycles based on water levels. When the second water storage tank 238 fills to a midpoint level, the controller 876 initiates a new ice-making cycle, thus consuming the collected melt water before additional overflow occurs. The control algorithm prioritizes the use of reclaimed melt water over fresh water, maintaining mass balance and reducing water consumption. The system only accesses fresh supply water after ice has been dispensed or removed.

The system may include a defrost mode. The defrost mode removes accumulated ice or frost within the ice maker assembly 204 and its adjacent passages. The controller 876 initiates this mode at scheduled intervals or upon detecting restricted movement of the auger 364 or ice wheel 360. During defrost mode, a heater 898 positioned near the ice maker assembly 204 and chute plate 334 is energized to elevate local temperature above freezing. The controlled application of heat melts residual ice along the extruder and dispensing areas, allowing any melt water to drain freely toward the second water storage tank 238 through the drain hole 863 and check valve 338. The defrost mode prevents ice blockage, ensures reliable operation of the auger arm 364 and ice wheel 360, and maintains uniform ice quality over extended use cycles.

The heater 898 is operated under command of the controller 876 during defrost or maintenance phases. The heater 898 is typically mounted near the lower ice bin 352 or adjacent to the ice maker assembly 204. The controller 876 energizes the heater 898 for a defined time interval to prevent freezing of the dispensing mechanism or water path. The heater 898 may also be cycled periodically during an ice storage mode to maintain internal temperatures just above freezing, minimizing solidification of residual melt water. The controlled heater operation ensures that the system maintains optimal conditions for ice formation and dispensing without undesired freezing of moving components.

The water recirculation process transfers melt water collected in the second water storage tank 238 to the first water storage tank 222 for reuse in new ice production. The controller 876 activates the pump 256 when the level sensor 872 in the second water storage tank 238 indicates sufficient stored melt water. Water is then pumped through a one-way passage protected by the check valve 338 to prevent backflow. The first water storage tank 222 receives this recycled water, which is subsequently fed to the ice maker assembly 204 during ice extrusion. This closed-loop recirculation reduces overall water consumption, maintains system hygiene, and prevents overflow. Once transfer is complete, the controller 876 stops the pump 256 and resumes monitoring both tank levels.

The system may include a storage mode. The storage mode is a standby condition that maintains the chewable ice within the lower ice bin 352 at temperatures slightly above freezing. In this mode, the ice remains soft and chewable while melt water drains continuously toward the second water storage tank 238. The controller 876 deactivates the ice maker assembly 204 and may place the heater 898 in low-power operation to prevent refreezing. The pump 256 remains inactive unless the second water storage tank 238 reaches its high-level threshold. The system remains in storage mode until a sensor signal indicates that the second water storage tank 238 is full or that ice consumption beyond a threshold has occurred. The storage mode allows efficient energy use while ensuring the ice remains in optimal condition for dispensing.

The system may include a production mode. The production mode begins when the controller 876 receives a signal from the level sensor 872 indicating that the second water storage tank 238 is full, or when the first water storage tank 222 becomes empty following ice consumption. In this mode, the controller 876 activates the pump 256 to transfer melt water from the second water storage tank 238 to the first water storage tank 222. The ice maker assembly 204 is then energized to begin ice extrusion using the available water. As ice is produced, melt water levels decrease, and fresh ice accumulates in the lower ice bin 352. Once the first water storage tank 222 is depleted or the second water storage tank 238 becomes empty, the controller 876 terminates the production mode and transitions to storage mode. This operation ensures balanced water management and efficient use of both recycled and fresh water resources.

FIG. 34 is a flowchart of a method 877 that represents the operation of the water management system 874 under command of the controller 876. The flowchart may represent control logic and/or algorithms that are stored within the controller 876. The process begins at step 878, which corresponds to a system idle state where the controller 876 continuously monitors the level sensor 872 located in the second water storage tank 238 and the level sensor 226 located in the first water storage tank 222. Both sensors provide signals to indicate the current water levels in their respective tanks. Next the method 877 moves on to step 880 where it is determined if the water level in the second water storage tank 238 exceeds a threshold. If the water level does not exceed the threshold, the method 877 recycles back to step 878.

If the water level in the second water storage tank 238 does exceed the threshold (e.g., when the level sensor 872 detects that the water level in the second water storage tank 238 has reached a predetermined activation threshold), the controller 876 activates the pump at step 882. In this step, the controller 876 energizes the pump 256 to transfer melt water from the second water storage tank 238 through a connecting line to the first water storage tank 222. The transferred water is used as feed water for the ice maker assembly 204.

During the pumping process at step 882, the controller 876 also monitors the output from the level sensor 226 in the first water storage tank 222 at step 884 to determine if the water level in the first tank is greater than a threshold. If the water level in the first tank is not greater than the threshold, the pump 256 remains activated according to step 882. If the level sensor 226 indicates that the first water storage tank 222 has reached a full-level threshold, the controller 876 deactivates the pump 256 at step 886 to prevent overfilling. In addition, at step 884 the controller 876 monitors the runtime of the pump 256. If the pump 256 operates for a preset duration (e.g., a time threshold) without causing the first water storage tank 222 to reach its full level, a timeout condition is detected. If the timeout condition is detected (e.g., the runtime of the pump 256 exceeded the threshold), the controller 876 then deactivates the pump 256 and records the event to prevent unnecessary cycling.

When sufficient water is present in the first water storage tank 222, the controller 876 advances to the ice production mode 888. In this mode, the ice maker assembly 204 operates to produce chewable ice using the water transferred from the second water storage tank 238. Once ice production is complete, the system transitions to a monitoring state in which the controller 876 observes ice consumption at step 890. Ice consumption occurs when the consumer dispenses ice or removes the ice bin assembly 206. Next, it is determined if the ice consumption has exceeded a threshold at step 892. If the ice consumption has not exceeded the threshold, the system continues monitoring ice consumption as step 890.

If the ice consumption has exceeded threshold, the controller 876 performs a fresh water inlet control step 894. In this step, if both the first water storage tank 222 and the second water storage tank 238 are empty, the controller 876 opens a fresh water inlet valve to deliver new water from the household/domestic supply line into the first water storage tank 222. This step ensures that the system maintains proper mass balance and only uses new water when the recycled melt water has been depleted.

Upon completion of the pumping or ice production sequence, the controller 876 enters a return-to-monitoring state (e.g., the controller 876 returns to step 878). In this state, the controller 876 again monitors the level sensors 872 and 226 to determine the next operational action. The control cycle thereby repeats continuously to maintain steady water and ice levels.

The system also includes an overflow protection path. When the water level in the second water storage tank 238 exceeds the buffer volume located above the level sensor 872, excess water exits through the overflow port 870 to a designated drain passage. This passive overflow feature provides a final safety measure against flooding and ensures reliable containment of melt water during abnormal conditions such as prolonged inactivity or extreme temperature variation.

Through this sequence of steps, the method 877 defines a closed-loop management process that prioritizes reuse of melt water, prevents overflow, and maintains steady ice production. The controller 876 automatically executes each transition based on real-time sensor feedback, resulting in an efficient, self-regulating water management system for the chewable ice maker. It should be understood that the flowchart in FIG. 34 is for illustrative purposes only and that the method should not be construed as limited to the flowchart in FIG. 34. Some of the steps of the method may be rearranged while others may be omitted entirely.

It should be understood that the designations of first, second, third, fourth, etc. for any component, state, or condition described herein may be rearranged in the claims so that they are in chronological order with respect to the claims. Furthermore, it should be understood that any component, state, or condition described herein that does not have a numerical designation may be given a designation of first, second, third, fourth, etc. in the claims if one or more of the specific component, state, or condition are claimed.

The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments may be combined to form further embodiments that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics may be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. As such, embodiments described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.