Water spillage management for in the door ice maker Number:7,437,885 from the United States Patent and Trademark Office (PTO) owispatent A refrigerator freezer having an ice maker positioned on a refrigerator compartment or freezer compartment door. The ice maker is arranged to prevent or manage spills from the ice maker in the event the door on which the ice maker is mounted is opened or closed when unfrozen water is present in the ice maker. Spill management embodiments for a number of fixed and movable tray ice makers are disclosed.<H management, spillage, Water, spillage, , 7437885.html, Patent, pto, 7437885

Title: Water spillage management for in the door ice maker

Abstract: A refrigerator freezer having an ice maker positioned on a refrigerator compartment or freezer compartment door. The ice maker is arranged to prevent or manage spills from the ice maker in the event the door on which the ice maker is mounted is opened or closed when unfrozen water is present in the ice maker. Spill management embodiments for a number of fixed and movable tray ice makers are disclosed.

Patent Number: 7,437,885 Issued on 10/21/2008 to Wu, et al.

Inventors: Wu; Guolian (St. Joseph, MI), Chase; Kevin M. (Granger, IN), Fischer; Marcus R. (St. Joseph, MI), Pastryk; Jim J. (Sawyer, MI), Olsson; Shawn F. (St. Joseph, MI), Wilcox; Michele E. (Stevensville, MI), Visin; Jerry M. (Benton Harbor, MI), Lewis; Martin D. (Paw Paw, MI)
Assignee: Whirlpool Corporation (Benton Harbor, MI)

Appl. No.: 10/973,559

Filed: October 26, 2004

Current U.S. Class: 62/344 ; 62/353

Current International Class: F25C 5/18 (20060101); F25C 1/00 (20060101)

Field of Search: 62/351,350,344,340,353 220/828,833

References Cited [Referenced By]

U.S. Patent Documents


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4967995	November 1990	Burgess
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2004/0237563	December 2004	Lee et al.

Primary Examiner: Jiang; Chen-Wen
Attorney, Agent or Firm: Goodwin; Kirk Lafrenz; Michael D.

Claims

We claim:

1. A refrigerator freezer comprising: a freezer compartment maintained at a temperature below 0.degree. C. and having an insulated freezer compartment door; a refrigerator compartment maintained at a temperature above 0.degree. C. and having an insulated refrigerator compartment door; a refrigeration system for cooling the freezer compartment and the refrigerator compartment; an automatic ice maker positioned on one of the refrigerator compartment door and the freezer compartment door; a tray mounted below the ice maker arranged to collect water spillage that may occur when door on which the ice maker is positioned is moved when water is present in the ice maker.

2. The refrigerator freezer according to claim 1, further including a drain line leading from the tray to a water disposal container.

3. The refrigerator freezer according to claim 2, further including a machinery compartment, and wherein the refrigeration system includes a drain pan located in the machinery compartment, and further wherein the drain pan is the water disposal container.

4. The refrigerator freezer according to claim 3, further including a pump to pump water from the tray to the drain pan.

5. The refrigerator freezer according to claim 1, further including a heater for the tray.

6. The refrigerator freezer according to claim 5, further including a defrost heater for the refrigeration system wherein the tray heater is connected to be energized when the defrost heater is energized.

7. The refrigerator freezer according to claim 5, further including a control for the tray heater wherein the tray heater is periodically energized.

8. The refrigerator freezer according to claim 5, further including a spill sensor and control arranged to detect the presence of water in the tray, wherein the control energizes the tray heater when the spill sensor detects water in the tray.

9. The refrigerator freezer according to claim 1, wherein the refrigerator freezer includes an ice storage bin and wherein the automatic ice maker and ice storage bin are positioned on the freezer compartment door.

10. The refrigerator freezer according to claim 1, wherein the refrigerator freezer includes an ice storage bin and the automatic ice maker and ice storage bin are positioned on the refrigerator compartment door, and wherein the refrigerator freezer further includes an air duct leading to the automatic ice maker and ice storage bin from a source of below 0.degree. C. air for supplying air cooled to below 0.degree. C. to the automatic ice maker and to the ice storage bin.

11. The refrigerator freezer according to claim 10, further including an insulated sub-compartment on the refrigerator compartment door for the automatic ice maker, and wherein the ice storage bin is insulated to maintain below freezing temperatures in the ice storage bin.

12. The refrigerator freezer according to claim 1, further including a door damper connected to the one of the refrigerator compartment door and the freezer compartment door on which the ice maker is positioned.

13. The refrigerator freezer according to claim 1, wherein the automatic ice maker includes an ice mold and a hinged cover for substantially covering the ice mold, and wherein the ice maker is arranged to open the hinged cover during ice harvesting cycles.

14. A refrigerator freezer comprising: a freezer compartment maintained at a temperature below 0.degree. C. and having an insulated freezer compartment door; a refrigerator compartment maintained at a temperature above 0.degree. C. and having an insulated refrigerator compartment door; a refrigeration system for cooling the freezer compartment and the refrigerator compartment; an automatic ice maker positioned on one of the refrigerator compartment door and the freezer compartment door comprising: an ice mold; an ice piece stripper having a base strip mounted along one edge of the ice mold, and having a plurality of fingers extending from the base strip and positioned above a portion of the ice mold; an ice rake having a plurality of tines rotatably mounted above the ice mold and arranged for the tines to rotate between the plurality of fingers and through the ice mold to carry ice pieces out of the ice mold; and a cover including a longitudinally extending domed portion substantially covering the ice mold, wherein the domed portion is hinged to the ice maker along a first edge and includes a plurality of tongues adjacent a second edge and arranged to extend into and substantially fill the spaces between adjacent ice piece stripper fingers.

15. The refrigerator freezer according to claim 14, further including an ice cube storage bin, and wherein the cover is arranged to open during ice harvesting cycles to permit the ice rake to rotate through the ice mold and ice pieces to fall into the ice storage bin.

16. The refrigerator freezer according to claim 15, wherein the automatic ice maker includes a motor arranged to drive the ice rake and to open the cover during ice harvesting cycles.

17. The refrigerator freezer according to claim 16, wherein the automatic ice maker further includes one or more gears drivingly connecting the ice maker motor to the ice rake.

18. The refrigerator freezer according to claim 17, wherein the automatic ice maker further includes a cam driven by the ice maker motor to open the cover when the ice maker motor operates to drive the ice rake.

19. The refrigerator freezer according to claim 14, wherein the first edge of the cover closes against the ice mold and the second edge of the cover closes against the base strip of the ice piece stripper.

20. The refrigerator freezer according to claim 19, wherein the cover includes end walls closing the domed portion, and wherein a first portion of the end walls close against the ice mold.

21. The refrigerator freezer according to claim 19, wherein the ice mold includes a plurality of hinge pins along one edge of the ice mold, and the cover includes a plurality of hinge elements arranged to engage and pivot on the hinge pins.

22. The refrigerator freezer according to claim 21, wherein the ice piece stripper is arranged with a finger at each end overlying a portion of the respective end of the ice mold, and wherein a second portion of the end walls of the cover close against the ice piece stripper finger at the respective ends of the ice piece stripper.

23. The refrigerator freezer according to claim 14, wherein the ice mold includes a plurality of semi-cylindrical cavities for forming ice pieces.

24. The refrigerator freezer according to claim 23, wherein the rotatably mounted ice rake is mounted adjacent the top edge of the semi-cylindrical cavities and is positioned substantially along the center line of the semi-cylindrical cavities.

25. The refrigerator freezer according to claim 24, wherein the ice piece stripper fingers are arranged to extend from the base strip along one edge of the ice mold to the ice rake.

26. The refrigerator freezer according to claim 14, wherein the ice piece stripper is positioned on the ice mold to define a water recovery channel between the ice piece stripper and the ice mold, and wherein the cover overlies and encloses the water recovery channel.

27. The refrigerator freezer according to claim 14, further including a door damper connected to the one of the refrigerator compartment door and the freezer compartment door on which the ice maker is positioned.

28. A refrigerator freezer comprising: a freezer compartment maintained at a temperature below 0.degree. C. and having an insulated freezer compartment door; a refrigerator compartment maintained at a temperature above 0.degree. C. and having an insulated refrigerator compartment door; a refrigeration system for cooling the freezer compartment and the refrigerator compartment; an automatic ice maker positioned on one of the refrigerator compartment door and the freezer compartment door; a tray mounted below the ice maker arranged to collect water spillage that may occur when door on which the ice maker is positioned is moved when water is present in the ice maker; and a spill sensor to detect water in the tray and arranged to provide a signal to the user that a spill has occurred.

29. The refrigerator freezer according to claim 28, wherein the spill sensor comprises two groups of conductive elements positioned in the tray, and wherein the two groups of conductive elements are connected to a spill detecting circuit.

30. The refrigerator freezer according to claim 29, wherein the spill detecting circuit includes a signal to alert the user that a spill has occurred.

31. The refrigerator freezer according to claim 30, wherein the signal is an LED device to provide a visual signal that a spill has occurred.

32. The refrigerator freezer according to claim 30, wherein the signal is a beeper to provide an audible alert that a spill has occurred.

33. The refrigerator freezer according to claim 30, further including a drain line from the tray leading to a water disposal container and a pump to pump water from the tray to a water disposal container and the spill detecting circuit includes an output to activate the pump.

34. The refrigerator freezer according to claim 28, further including a tray heater wherein the spill sensor actives the tray heater when a spill has occurred.

35. The refrigerator freezer according to claim 28, further including a door damper connected to the one of the refrigerator compartment door and the freezer compartment door on which the ice maker is positioned.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is related to the following U.S. patent applications filed concurrently herewith: US20020155, US20040162 and US20040111.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to ice makers positioned on a refrigerator or freezer compartment door. According to the invention the ice makers can be arranged to prevent or manage spills of water from the ice maker in the event the door on which the ice maker is mounted is opened and closed when unfrozen water is present in the ice maker.

2. Description of the Related Art

Manually filled ice cube trays having a cover or lid to prevent spills of water are known. Ice makers located on a refrigerator or freezer compartment door that do not include spill management features are known in the art.

Side by side refrigerator freezers having ice cube storage and dispenser mechanisms on the freezer door to supply an ice and water dispenser on the face of the freezer compartment door are well known in the art.

A variety of fixed ice mold and flexible tray automatic ice makers are known in the art.

SUMMARY OF THE INVENTION

The invention relates to a refrigerator freezer comprising having a freezer compartment maintained at a temperature below 0.degree. C., an insulated freezer compartment door, a refrigerator compartment maintained at a temperature above 0.degree. C., an insulated refrigerator compartment door, a refrigeration system for cooling the freezer compartment and the refrigerator compartment and an automatic ice maker positioned on one of the refrigerator compartment door and the freezer compartment door. A tray is mounted below the ice maker arranged to collect water spillage that may occur when door on which the ice maker is positioned is moved when water is present in the ice maker.

A drain line can lead from the tray to a water disposal container. The water disposal container can be a drain pan located in the machinery compartment.

In another aspect of the invention the tray can have a heater. The tray heater can be connected to be energized when the refrigeration system defrost heater is energized.

In another aspect of the invention a spill sensor and control can be provided to detect the presence of water in the tray. The control can energize the tray heater when the spill sensor detects water in the tray.

In another aspect the invention relates to a refrigerator freezer having a freezer compartment maintained at a temperature below 0.degree. C., an insulated freezer compartment door, a refrigerator compartment maintained at a temperature above 0.degree. C., an insulated refrigerator compartment door, a refrigeration system for cooling the freezer compartment and the refrigerator compartment and an automatic ice maker positioned on one of the refrigerator compartment door and the freezer compartment door. The ice maker includes an ice mold, an ice piece stripper having a base strip mounted along one edge of the ice mold having a plurality of fingers extending from the base strip and positioned above a portion of the ice mold. The ice maker includes an ice rake having a plurality of tines rotatably mounted above the ice mold and arranged for the tines to rotate between the plurality of fingers and through the ice mold to carry ice pieces out of the ice mold. The ice maker also includes a cover including a longitudinally extending domed portion substantially covering the ice mold. The domed portion of the cover is hinged to the ice maker along a first edge and includes a plurality of tongues adjacent a second edge arranged to extend into and substantially fill the spaces between adjacent ice piece stripper fingers.

The cover is arranged to open during ice harvesting cycle to permit the ice rake to rotate through the ice mold and ice pieces to fall into an ice storage bin positioned below the ice maker. The ice maker includes a motor arrange to drive the ice rake and to open the cover during ice harvesting cycles. The ice maker includes a cam driven by the ice maker motor to open the cover when the ice maker motor operates to drive the ice rake.

The first edge of the cover closes against the ice mold and the second edge of the cover closes against the base strip of the ice piece stripper.

The ice piece stripper can be positioned on the ice mold to define a water recovery channel between the ice piece stripper and the ice mold. The cover can enclose the water recovery channel.

In another aspect the invention relates to a refrigerator freezer having a freezer compartment maintained at a temperature below 0.degree. C., an insulated freezer compartment door, a refrigerator compartment maintained at a temperature above 0.degree. C., an insulated refrigerator compartment door, a refrigeration system for cooling the freezer compartment and the refrigerator compartment and an automatic ice maker positioned on one of the refrigerator compartment door and the freezer compartment door. The ice maker includes an ice mold and a flexible ice piece stripper positioned above a first portion of the ice mold having a plurality of slits forming a plurality of fingers. The ice maker further includes an ice rake having a plurality of tines rotatably mounted above the ice mold and arranged for the tines to rotate through the plurality of slits and through the ice mold to carry ice pieces out of the ice mold. The ice maker further includes a hood extending above a second portion of the ice mold.

The flexible ice piece stripper can extend from the ice rake to a first edge of the ice mold and can be arranged to substantially cover the first portion of the ice mold from the centerline of the ice mold to the first edge of the ice mold. The hood can extend from a second edge of the ice mold substantially to the center line of the ice mold above the ice mold to allow the ice rake to rotate through the ice mold.

In another aspect the invention relates to a refrigerator freezer having a freezer compartment maintained at a temperature below 0.degree. C., an insulated freezer compartment door, a refrigerator compartment maintained at a temperature above 0.degree. C., an insulated refrigerator compartment door, a refrigeration system for cooling the freezer compartment and the refrigerator compartment and an automatic ice maker positioned on one of the refrigerator compartment door and the freezer compartment door. The ice maker includes an ice mold and an ice piece stripper having a base strip and a plurality of fingers positioned above a first portion of the ice mold. The ice mold also includes an ice rake having a plurality of tines rotatably mounted above the ice mold and arranged for the tines to rotate between the plurality of fingers and through the ice mold to carry ice pieces out of the ice mold and having a flexible web extending from adjacent tines to at least partially fill the gap between adjacent tines. The ice maker includes a motor for rotatably driving the ice rake to harvest ice pieces during harvest cycles and arranged to park the ice rake with the plurality of tines and flexible webs lying substantially in a plane with the plurality of fingers between harvesting cycles. A hood extends above a second portion of the ice mold.

In another aspect the invention relates to a refrigerator freezer having a freezer compartment maintained at a temperature below 0.degree. C., an insulated freezer compartment door, a refrigerator compartment maintained at a temperature above 0.degree. C., an insulated refrigerator compartment door, a refrigeration system for cooling the freezer compartment and the refrigerator compartment, an ice maker support on one of the refrigerator compartment or freezer compartment doors and arranged to support an ice maker spaced from the inner door panel wherein ice cubes harvested from the ice maker can fall into an ice storage bin positioned below the ice maker and an automatic ice maker arranged to be mounted on the ice maker support. The ice maker includes an ice mold and an ice piece stripper having a base strip and plurality of fingers positioned above a first portion of the ice mold. The base strip extends over a portion of the ice mold. The ice maker includes an ice rake having a plurality of tines rotatably mounted above the ice mold and arranged for the tines to rotate between the plurality of fingers and through the ice mold to carry ice pieces out of the ice mold. The ice maker further includes a hood extending above a second portion of the ice mold.

The ice piece stripper and hood can be integrally formed of plastic material. The ice rake can be formed of metal and can be mounted in contact with the ice mold and arranged to be heated by conduction from the ice mold during ice harvesting cycles. The ice maker includes a motor for rotatably driving the ice rake and the motor can be arranged to park the ice rake with the plurality of tines lying substantially in a plane with the plurality of fingers between harvesting cycles.

In another aspect the invention relates to a refrigerator freezer having a freezer compartment maintained at a temperature below 0.degree. C., an insulated freezer compartment door, a refrigerator compartment maintained at a temperature above 0.degree. C., an insulated refrigerator compartment door, a refrigeration system for cooling the freezer compartment and the refrigerator compartment and an automatic ice maker positioned on one of the refrigerator compartment door and the freezer compartment door. The ice maker includes a movable ice piece tray, a housing moveably supporting the ice piece tray for movement between a fill and ice making position and a harvest position and a sealing surface for containing water when the ice mold is in fill and ice making position.

The housing can include a rear containment wall, a front containment wall and end containment walls. The ice piece tray includes a mold insert having a plurality of recesses for forming ice pieces and an upwardly extending lip around the plurality of recesses forming the sealing surface. When the ice piece tray is in the fill and ice making position the upwardly extending lip is positioned outside the front, rear and end containment walls.

In another aspect the invention relates to a refrigerator freezer having a freezer compartment maintained at a temperature below 0.degree. C., an insulated freezer compartment door, a refrigerator compartment maintained at a temperature above 0.degree. C., an insulated refrigerator compartment door, a refrigeration system for cooling the freezer compartment and the refrigerator compartment and an automatic ice maker positioned on one of the refrigerator compartment door and the freezer compartment door. The ice maker includes a flexible tray having a plurality of cavities and sidewalls extending above the cavities to prevent water from splashing out of the tray in the event the door on which the ice maker is positioned is moved when water is present in the ice maker. The ice maker also includes a support for rotatably mounting the flexible tray between ice forming and ice harvesting positions and a drive mechanism for rotating the flexible tray between the ice forming and ice harvesting positions and twisting the flexible tray in the harvesting position to release ice pieces.

The ice maker can include two connected trays positioned facing opposite directions rotatably mounted between ice forming and ice harvesting positions. The ice trays can be integrally formed and share a bottom wall.

In another aspect the invention relates to a refrigerator freezer having a freezer compartment maintained at a temperature below 0.degree. C., a hinged insulated freezer compartment door, a refrigerator compartment maintained at a temperature above 0.degree. C., a hinged insulated refrigerator compartment door, a refrigeration system for cooling the freezer compartment and the refrigerator compartment, an automatic ice maker positioned on one of the refrigerator compartment door and the freezer compartment door and a door damper connected to the one of the refrigerator compartment door and the freezer compartment door on which the ice maker is positioned.

The door damper can be arranged to engage the door for at least a portion of the range of motion upon opening and at least a portion of the range of motion during closing of the door.

The door damper can be a spring loaded damper mounted in the machinery compartment and connected to one of the door hinges of the one of the refrigerator compartment door and the freezer compartment door on which the ice maker is positioned. The door damper can be connected to the door hinge in a position for the door damper to go over center when the one of the refrigerator compartment door and the freezer compartment door on which the ice maker is positioned opens and closes.

In one aspect of the invention the damper can be a hydraulic spring loaded damper.

In another aspect of the invention the damper can be a gas spring loaded damper.

In another aspect of the invention the damper is a rotary damper. The rotary damper can be a two way rotary damper.

In another aspect the invention relates to a refrigerator freezer having a freezer compartment maintained at a temperature below 0.degree. C., an insulated freezer compartment door, a refrigerator compartment maintained at a temperature above 0.degree. C., an insulated refrigerator compartment door, a refrigeration system for cooling the freezer compartment and the refrigerator compartment and an automatic ice maker positioned on one of the refrigerator compartment door and the freezer compartment door. A tray is mounted below the ice maker arranged to collect water spillage that may occur when door on which the ice maker is positioned is moved when water is present in the ice maker The tray includes a spill sensor to detect water in the tray and arranged to provide a signal to the user that a spill has occurred.

The spill sensor can comprise two groups of conductive elements positioned in the tray. The two groups of conductive elements are connected to a spill detecting circuit. The spill detecting circuit can include a signal to alert the user that a spill has occurred. The signal can be an LED device to provide a visual signal that a spill has occurred.

In another aspect the signal can be an audible signal that a spill has occurred.

In another aspect the refrigerator freezer can include a drain line leading from the tray and a pump to pump water from the tray to a water disposal container. The spill detecting circuit can include an output to activate the pump.

In another aspect the invention relates to a refrigerator freezer having a freezer compartment maintained at a temperature below 0.degree. C., an insulated freezer compartment door, a refrigerator compartment maintained at a temperature above 0.degree. C., an insulated refrigerator compartment door, a refrigeration system for cooling the freezer compartment and the refrigerator compartment, an automatic ice maker positioned on the inner door of the freezer compartment door and an ice storage bin positioned below the ice maker. The ice maker can include a cover pivotally mounted adjacent the top of the ice maker and arranged to enclose the ice maker in a first position and to form an ice chute from the ice maker to the ice storage bin in a second position.

The cover can be pivotally mounted adjacent the top of the ice maker adjacent the side of the ice maker opposite the inner door. The cover can include an actuator connected to the cover and arranged to pivot the cover about a hinge point. The actuator can be arranged to engage the top wall of the freezer compartment when the freezer compartment door is closed. The cover can include a spring mechanism to bias the cover toward the first position.

The ice cube storage bin can be removable from the freezer compartment door when the cover is in the first position.

In another aspect the invention relates to a refrigerator freezer having a freezer compartment maintained at a temperature below 0.degree. C., an insulated freezer compartment door, a refrigerator compartment maintained at a temperature above 0.degree. C., an insulated refrigerator compartment door, a refrigeration system for cooling the freezer compartment and the refrigerator compartment an automatic ice maker mounted on one of the refrigerator compartment door and the freezer compartment door and an ice storage bin positioned below the ice maker. The ice maker includes an ice mold and a heater for the ice mold. The ice maker is rotatably mounted for movement to a first position for filing the ice mold with water and for forming ice cubes and to second substantially inverted position for harvesting ice cubes.

The ice maker can include a temperature sensor arranged to determine when ice cubes are frozen and to initiate operation of the heater and to cause the ice maker to rotate to the second position. The ice maker can further include a substantially fixed ice rake positioned over the ice mold when the ice maker is in the first position and can be arranged to engage ice cubes in the ice mold as the ice maker is rotated to the second position.

In another aspect the invention relates to a refrigerator freezer having a freezer compartment maintained at a temperature below 0.degree. C., an insulated freezer compartment door, a refrigerator compartment maintained at a temperature above 0.degree. C., insulated refrigerator compartment door, a refrigeration system for cooling the freezer compartment and the refrigerator compartment and an automatic ice maker mounted on one of the refrigerator compartment door and the freezer compartment door. The ice maker includes an ice mold and a heater for the ice mold. The ice mold is rotatably mounted for movement to a first position for filing the ice mold with water and for forming ice cubes and to second substantially inverted position for harvesting ice cubes from the mold.

The ice mold includes extended side walls arranged to contain water in the ice mold in the event the door on which the automatic ice maker is mounted is moved when unfrozen water is present in the ice mold. The ice mold can further include a lip along the distal edge of one side wall. The lip can include a return edge directed toward the ice cube cavities arranged to define a channel to retain water formed when the ice mold is heated to harvest ice cubes as the ice mold is rotated to the second position.

The ice maker can include a substantially fixed rake positioned above the ice mold when the ice mold is in the first position and arranged to engage ice cubes in the ice mold as the ice mold is rotated to the second position. The ice maker can include a temperature sensor to determine when ice cubes are frozen and a motor to rotate the ice mold between the first position and the second position.

In another aspect the invention relates to a refrigerator freezer having a freezer compartment maintained at a temperature below 0.degree. C., an insulated freezer compartment door, a refrigerator compartment maintained at a temperature above 0.degree. C., an insulated refrigerator compartment door, a refrigeration system for cooling the freezer compartment and the refrigerator compartment and an automatic ice maker mounted on one of the refrigerator compartment door and the freezer compartment door. The ice maker includes an ice maker control, a generally rectangular ice mold, a fixed extension extending upwardly from one longitudinal edge of the ice mold and a hinged wall extending upwardly from the opposite longitudinal edge of the ice mold pivotally mounted to the ice mold. The ice maker also includes an ice rake rotatably mounted above the ice mold and operably connected to the ice maker control and an operator in the ice maker control arranged to move the hinged wall to a horizontal position in conjunction with operation of the ice rake.

The operator can be a lever in the ice maker control operably connected to the hinged wall. The ice maker control can include a cam arranged to operate the lever. The cam can be connected to rotate when the ice maker control rotates the ice rake.

The hinged wall can be biased to the upright position and the cam can be arranged to operate the lever to move the hinged wall to a horizontal position after the ice rake rotates into the ice mold. The hinged wall can include a plurality of raised surfaces on the upper surface of the hinged wall when it is positioned in the horizontal position. The raised surfaces can extend generally perpendicular to the ice rake.

In another aspect the invention relates to a method of making ice in a refrigerator freezer in which an automatic ice maker is mounted on one of the refrigerator or freezer compartment doors. The method includes the steps of operating the refrigerator freezer to provide cooling to the refrigerator and freezer compartments, filling the ice mold with water, preventing spills of water from the ice maker when the refrigerator or freezer compartment door on which the ice maker is mounted is opened or closed and harvesting ice pieces from the ice mold after the water has frozen.

The step of preventing spills can include providing a tray below the ice maker to catch any water splashing out of the ice maker. The method of making ice can further include operating a tray heater to melt any ice present in the tray. The step of preventing skills can include draining water from the tray to a water disposal container.

In another aspect the ice maker can include a cover for the ice maker and the step of preventing spills includes closing the cover and the step of harvesting ice pieces includes opening the cover.

In another aspect the ice maker includes an ice piece stripper and an ice rake having a plurality of tines rotatably positioned over the ice maker and arranged for the tine to rotate through the ice piece stripper and the ice maker mold. The step of preventing spills can include arranging the ice piece stripper and ice rake to substantially enclose a portion of the ice maker.

In another aspect the ice maker includes a flexible tray having a plurality of cavities. The step of preventing spills can include providing the flexible tray with sidewalls extending above the cavities to prevent water from splashing out of the tray. The flexible tray can comprise two interconnected trays positioned in opposite directions. Each tray can have sidewalls extending above the cavities when the ice tray is in the upright position.

In another aspect the refrigerator freezer can include an ice cube storage bin positioned below the automatic ice maker and the ice maker can include a movable cover. The step of harvesting ice cubes can include opening the cover to form a chute for ice cubes into the ice cube storage bin.

In another aspect the ice maker can include an ice mold rotatably mounted between a filling and ice cube forming position and a substantially inverted ice harvesting position. The method of preventing spills can include providing the ice mold with extended side walls with one of the side walls having a lip defining a channel. The step of harvesting ice pieces can include rotating the ice mold to harvest ice pieces and retaining any water melted during the harvest cycle in the channel. The step of harvesting can include returning water in the channel to the ice mold as the ice mold returns to the filling and ice formation position.

In another aspect the ice maker can include an ice mold have a fixed extension on one side of the ice mold and a hinged wall on the other side of the ice mold. The step of harvesting ice pieces can include rotating an ice rake into the ice mold and rotating the hinged wall from a vertical position to a horizontal position over the ice mold.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of bottom freezer refrigerator comprising one embodiment of an in the door ice maker according to the invention.

FIG. 1B is a partial perspective view of the bottom freezer refrigerator illustrated in FIG. 1A with a refrigerator compartment door open illustrating an ice maker according to the invention positioned on the door above an ice cube storage bin and ice dispenser.

FIG. 2 is a perspective view of a freezer door illustrating the application of an ice maker according to the invention to a side by side refrigerator freezer.

FIG. 3 is a perspective view on one embodiment of an ice maker according to the invention having a tray for catching spills and a cover.

FIG. 4 is a perspective view of the ice maker of FIG. 3 with the cover closed.

FIG. 5 is a perspective view of another embodiment of an ice maker according to the invention having a cover and a water recovery channel.

FIG. 6 is a perspective view of the ice maker of FIG. 5 with the cover closed.

FIG. 7 is a perspective view of another embodiment of an ice maker according to the invention having a flexible ice stripper and a partial hood.

FIG. 8 is a perspective view of another embodiment of an ice maker according to the invention having a cover.

FIG. 9 is a partial perspective view of another embodiment of an ice maker according to the invention positioned on a refrigerator compartment or freezer compartment door with the ice mold in the closed position.

FIG. 10 is a partial perspective view of the ice maker of FIG. 9 with the ice mold partially open.

FIG. 11 is a cross sectional view through the ice maker of FIG. 9 illustrating the relationship between the ice mold and the housing in the closed position.

FIG. 12A is a partial perspective view of a prior art side by side refrigerator freezer having the ice maker positioned in the freezer compartment.

FIG. 12B is a partial perspective view of a side by side refrigerator freezer having an ice cube maker according to the invention positioned on the freezer compartment door.

FIG. 13A is a schematic side view illustrating an ice maker according to the invention positioned on a freezer compartment door having a pivotal cover in the closed position.

FIG. 13B is a partial schematic side view of the ice maker according to FIG. 13A illustrating the hinging of the cover to the ice maker in the freezer compartment door open position.

FIG. 14A is a schematic side view illustrating the ice maker of FIGS. 13A and 13B with the cover opened and ice cubes falling into the underlying ice cube storage bin.

FIG. 14B is a partial schematic side view similar to FIG. 13B illustrating the hinging of the cover to the ice maker in the freezer compartment door closed position.

FIG. 15 is a perspective view of another embodiment of twist tray ice maker according to the invention.

FIG. 16 is a perspective view of another embodiment of a twist tray ice maker according to the invention having two trays.

FIG. 17 is a perspective view of another embodiment of a twist tray for use in a twist tray ice maker similar to the embodiments of FIG. 15 and FIG. 16 removed from the ice maker.

FIG. 18 is a partial sectional view of the twist tray of FIG. 17.

FIG. 19 is a perspective view of another embodiment of a twist tray for use in a twist tray ice maker similar to the embodiments of FIG. 15 and FIG. 16 removed from the ice maker.

FIG. 20A is a perspective view of another embodiment of a rotatable ice maker mold with the mold in the upright position.

FIG. 20B is a perspective view of the rotatable ice maker mold of FIG. 20A with the mold rotated 90 degrees.

FIG. 20C is a perspective view of the rotatable ice maker mold of FIG. 20A with the mold rotated 180 degrees.

FIG. 21A is a schematic cross section view of the rotatable ice maker mold in the position illustrated in FIG. 20A.

FIG. 21B is a schematic cross section view of the rotatable ice maker mold in the position illustrated in FIG. 20B.

FIG. 21C is a schematic cross section view of the rotatable ice maker mold in the position illustrated in FIG. 20C.

FIG. 22A is a schematic top view of another embodiment of an ice maker according to the invention.

FIG. 22B is a schematic cross section view of the ice maker of FIG. 22A illustrating the beginning of an ice harvesting cycle.

FIG. 22C is a schematic cross section view of the ice maker of FIG. 22A illustrating a subsequent point in the ice harvesting cycle.

FIG. 23 is a partial perspective view of the machinery compartment for a refrigerator freezer having an ice maker positioned on the freezer compartment door of a side by side refrigerator freezer illustrating one embodiment of a door damper for use with ice makers according to the invention.

FIG. 24A is a partial schematic view illustrating another embodiment of a door damper for use with ice makers according to the invention.

FIG. 24B is a partial perspective view of the damper of FIG. 24A.

FIG. 25 is a circuit diagram illustrating spill sensor elements that can be used with ice maker embodiments according to the invention.

FIG. 26 is a block diagram illustrating operation of a refrigerator freezer including ice maker spill management according to the invention.

FIG. 27 is a circuit diagram illustrating electrical elements that can be used with ice maker embodiments according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

One of the most desired accessories for a household refrigerator is a through-the-door ice and water system. A through-the-door ice and water dispenser is desirable because it greatly simplifies the process of retrieving ice cubes, i.e. it eliminates opening the door, removing the ice cube storage bin, separating and scooping ice cubes, and pouring the ice cubes into a glass. The feature also can be viewed as an energy saver, since the freezer door is not opened as often.

In today's household refrigerator market, there are three basic configurations to choose from: a bottom freezer refrigerator in which the refrigerator compartment is located above the freezer compartment, a top-mount refrigerator in which the freezer compartment is located above the refrigerator compartment, and a side by side refrigerator in which the refrigerator compartment and the freezer compartment extend the entire height of the refrigerator.

In the side by side configuration the ice cube storage bin and dispenser can be positioned on the freezer compartment door. It would be advantageous to also position the ice maker on the freezer door to provide additional shelf storage space in the freezer compartment. Likewise, it would be desirable to provide ice and water dispensers for bottom freezer refrigerators. However, to do so essentially requires providing ice making and storage mechanisms in the refrigerator compartment or on a refrigerator compartment door.

With current ice making and dispensing technology, it has not been possible for a consumer to have an ice and water dispenser features on a bottom freezer refrigerator compartment door, or a side by side refrigerator freezer door with the ice and water dispenser mechanisms totally positioned on a door. One of the biggest challenges is how to manage water spillage that may occur when the door on which an ice cube maker is positioned is abruptly opened or closed when water is present in the ice mold. According to applicants' invention spillage of water from an ice maker positioned on a refrigerator or freezer compartment door is prevented or managed.

It should be noted that the embodiments described in this application share many of the same elements, such as a dispensing outlet mounted on the outside of a refrigerator or freezer compartment door, an ice cube storage bin and an ice dispenser. Similarly ice makers that are the subject of applicants' invention share many of the same elements. It will be understood that the operation of these elements will generally be the same for each embodiment, and a description of their operation will not be repeated for each embodiment, unless otherwise noted. As well, elements common to more than one embodiment will usually be identified with common numerals. For example, each of the ice maker embodiments can include an ice maker control, identified as ice maker control 33, and motor 35 in the embodiment of FIG. 2. Ice cubes 34 are illustrated and described as generally semicircular pieces of ice, although the inventive concepts described herein are not so limited, and are equally applicable to ice pieces having a cylindrical, rectilinear or other shape. As will be described in greater detail below the ice makers according to applicants' inventions can be used with side by side and bottom freezer refrigerator freezers.

Turning to FIGS. 1A, 1B, 2, 12A and 12B bottom freezer and side by side refrigerator freezers having an in the door ice maker and dispenser apparatus according to the invention can be seen. FIGS. 1A and 1B shows a bottom freezer refrigerator disclosed in greater detail in co-pending U.S. Patent Application US20040111 filed concurrently herewith by Anselmino et al, and entirely incorporated by reference in this application. Bottom freezer refrigerator 50 can have a cabinet 52 including a refrigerator compartment 54 maintained at above 0.degree. C. temperatures and a freezer compartment 56 maintained at below 0.degree. C. temperatures. Freezer compartment 56 is positioned in the bottom of cabinet 52 and refrigerator compartment 54 is positioned above freezer compartment 56. In the embodiment of FIGS. 1A and 1B, bottom freezer 50 can have two refrigerator compartment doors 68 and 69 arranged side by side. The bottom freezer refrigerator 50 configuration shown in FIGS. 1A and 1B is sometimes referred to as a French door bottom mount refrigerator freezer. Conventional door handles 44, 46 and 48 are shown on refrigerator compartment doors 68 and 69 and freezer compartment door 66. Those skilled in the art will readily understand that different handles, or no handles, can be provided for the doors as is well known in the art. A side by side refrigerator freezer embodying the invention is illustrated in FIGS. 2, 12A and 12B and described in detail below.

Refrigerator 50 can have a refrigeration system (not shown) for cooling the refrigerator compartment 54 and freezer compartment 56. The refrigeration system can include a compressor, condenser, evaporator and expansion device, all not shown, as is well known in the art. The compressor can be a variable speed compressor to provide variable cooling rates, again well known in the art. Refrigerator 50 can also have a control system (not shown) that can include temperature sensors (not shown) for the refrigerator compartment 54 and freezer compartment 56 connected to refrigerator and freezer compartment temperature controllers (not shown) to maintain the temperatures in the respective compartments at user selected temperatures. The evaporator (not shown) can be positioned in an evaporator compartment (not shown) that can be positioned along the back wall of the freezer compartment as is well known in the art.

Refrigerator compartment door 69 can include an ice and water dispenser 72 positioned on the face of the door. Ice and water dispenser 72 can be positioned on refrigerator compartment door 69 at a convenient height for user access as is well known in the art. A user interface 73 can be positioned adjacent ice and water dispenser 72 for users to select ice and water dispensing alternatives such as "quick ice" described below, and other refrigerator freezer operation parameters such as described in co-pending U.S. patent application Ser. No. 10/861,203 incorporated herein by reference.

An ice maker 82 can be mounted adjacent the top of refrigerator compartment door 69 spaced from inner door panel 70. An ice cube storage bin 84 can be positioned below ice maker 82 and arranged so that ice cubes harvested from ice maker 82 can fall through gap 93 into ice cube storage bin 84. Gap 93 can be provided between the rear of ice maker 82 and inner door 70 to direct ice cubes into ice cube storage bin 84. Ice cube storage bin 84 can rest on top of ice dispenser 86. An insulated cover 88 can be provided to substantially enclose ice maker 82. An insulated cover 90 can be provided to substantially enclose ice cube storage bin 84 and ice dispenser 86. Insulated covers 88 and 90 can form sub-compartments that can be maintained below 0.degree. C. to facilitate formation and storage of ice cubes. Insulated cover 88 can include one or more latching surfaces (not shown) arranged to hold cover 88 in place forming a below 0.degree. C. enclosure for ice maker 82 as refrigerator compartment door 69 is opened and closed in use. As described above, insulated cover 88 and insulated cover 90 allow the respective sub-compartments to be maintained at below 0.degree. C. temperatures without upsetting normal above 0.degree. C. temperatures in refrigerator compartment 54.

Insulated cover 90 can be pivotally mounted to inner door panel 70 with hinges 77. Hinging insulated cover 90 to inner door panel 70 can allow easy access to ice cube storage bin 84 to, for example, facilitate removal of ice cube storage bin 84 to bulk dispense ice cubes into a cooler or the like. Insulated cover 90 can be arranged so that it can be closed automatically as refrigerator compartment door 69 is closed. Insulated cover 90 can be provided with a gasket 79 to seal against a surface of inner door panel 70.

Insulated cover 90 can be omitted if ice cube storage bin 84 is formed of insulating material. In one embodiment, ice cube storage bin 84 can be formed of double wall plastic material with sufficient insulating properties to maintain ice cubes in the bin frozen and sufficiently cold to preclude individual cubes from melting together. Those skilled in the art will readily understand that suitable clear plastic materials such as described above can be used to form an insulated ice cube storage bin 84. Similarly, those skilled in the art will understand that if no insulating cover is provided below 0.degree. C. air flow can be directed into ice cube storage bin 84 in a manner to preclude undesirable leakage to the refrigerator compartment.

Ice cube storage bin 84 and ice dispenser 86 can be similar to the ice delivery system disclosed in U.S. Pat. No. 6,082,130, assigned to the assignee of this application and incorporated herein by reference. Those skilled in the art will understand that an ice delivery system such as disclosed in U.S. Pat. No. 6,082,130 can be used in the embodiment shown in FIGS. 1A and 1B, or can be provided with an insulating ice cube storage bin as described above, and can be positioned on refrigerator compartment door to cooperate with ice maker 82 and with ice and water dispenser 72. One approach to ice cube storage bin level sensing is described in U.S. Pat. No. 6,082,130 and those skilled in the art will understand that many ways to determine the level of ice cubes in an ice cube storage bin are known and can be used in place of the optical system described in the above identified patent application. Ice maker 82 and the ice and water dispenser 72 can be provided with water under control of a water valve control 94 and a water valve 95 that can be included in the bottom freezer refrigerator as is well known in the art. The water valve control 94 for the ice and water dispenser 72 and ice maker 82 can be a variable flow water system as disclosed in co-pending U.S. patent application Ser. No. 10/861,569 incorporated herein by reference.

In a bottom freezer embodiment as illustrated in FIGS. 1A and 1B below 0.degree. C. air can be supplied to ice maker 82 and ice cube storage bin 84 by an air delivery system that can lead from freezer compartment 56. The air delivery system can include a first air delivery portion 100 that can be positioned along one side of refrigerator compartment door 69 against inner door panel 70. The air delivery system can include a second air delivery portion 106 positioned along a side wall of refrigerator compartment 54 and leading down toward freezer compartment 56. First air delivery portion 100 can include a supply duct 102 and a return duct 104. Those skilled in the art will understand that first air delivery portion 100 can be a dual passage tube having two air passages forming supply duct 102 and return duct 104. First air delivery portion 100 can be formed of thermoformed or injection molded plastic material and can be covered or enclosed with insulating material such as rigid styrobead. Second air delivery portion 106 can similarly comprise a supply duct 108 and a return duct 110. Second air delivery portion 106 can be a dual passage tube formed of plastic material similar to first air delivery portion 100. The faces of first and second air delivery portions 100 and 106 can abut when refrigerator door 69 is closed and can be arranged so that supply ducts 102 and 108 and return ducts 104 and 110 are opposite one another, and can form a continuous passage when refrigerator compartment door 69 is closed. The face of first and second air delivery portions 100 and 106 can include suitable sealing surfaces for the supply and return ducts so that substantially air tight connections can be made when refrigerator compartment door 69 is closed. The air delivery system is described in greater detail in co-pending U.S. Patent Application US20040111 filed concurrently with this application and incorporated by reference as indicated above.

Turning to FIGS. 2 and 12B a side by side refrigerator freezer having an in the door ice maker and dispenser apparatus according to the invention can be seen. FIG. 12A illustrates a prior art side by side refrigerator freezer 10 having an ice maker assembly 22 positioned in the top of freezer compartment 16. Freezer compartment 16 can have one or more shelves 11 and one or more baskets 13 arranged for storing items in the freezer compartment 16. Freezer compartment door 20 can have one or more door shelves 21 arranged for storing items on the freezer compartment door 20. Similarly, refrigerator compartment 14 can have one or more shelves and one or more baskets or bins for storing items in the above 0.degree. C. refrigerator compartment. FIG. 12B illustrates a side by side refrigerator freezer 10 having an ice maker assembly 22' according to the invention positioned on the inside of freezer compartment door 20. Comparing FIGS. 12A and 12B relocation of ice maker assembly 22 to the freezer door 20 can result in a full additional shelf for increased storage in freezer compartment 16 with no decrease in freezer door 20 shelf storage space. Side by side refrigerator freezer 10 can be provided with a cabinet 12 forming a refrigerator compartment 14 and a freezer compartment 16 arranged side by side as is well known in the art. A refrigeration system (not shown) can be provided to maintain refrigerator compartment 14 at temperatures above 0.degree. C. and freezer compartment 16 at temperatures below 0.degree.