Methods and apparatus for mounting an ice maker

Abstract

An ice maker for a refrigerator having a freezer compartment with a top wall, side walls, a back wall, and a door opposite the back wall includes a mold body having at least one cavity for containing water therein for freezing into ice, and a control housing extending from the mold body. The control housing is configured to be coupled to a mounting surface of said freezer compartment, wherein the mounting surface includes at least one of the top wall, the side walls, the back wall, and the door of the freezer compartment.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to India Patent Application Serial Number 1752/CHE/2005, filed Nov. 30, 2005, which is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

This invention relates generally to ice makers, and more particularly, to methods and apparatus for mounting ice makers within a freezer compartment.

Some refrigerator freezers include an ice maker mounted within the freezer compartment. The ice maker includes a mold body having multiple cavities that receive water for ice production. Over time, the water is frozen and ice is formed in the mold body. The ice is deposited into and stored in an ice bucket. Typically a leveling arm senses the level of ice in the ice bucket. Ice is produced until the ice level is at a certain height within the bucket. Typically, the ice maker is mounted against a back wall of the freezer compartment directly above the ice bucket. The ice maker is mounted by brackets that are integral to the ice maker mold body. At least some known ice makers include a secondary bracket that is mounted to the back wall, and the integral brackets are coupled to the secondary bracket. However, increased material and/or labor costs are associated with the use of a secondary bracket.

The interaction of the secondary brackets and the integral brackets with the back wall lead to variability in the mounted position of the ice maker. For example, the back wall of the freezer compartment is typically formed by a case foam process. The process may cause uneven or non-planar surfaces for mounting the brackets. Additionally, the brackets may be uneven or non-level when mounted. Such variations may lead to an improper position or angular orientation of the leveling arm with respect to the ice bucket. As a result, the position of the leveling arm with respect to the ice bucket may be varied, leading to too much or too little ice being produced by the ice maker and stored in the ice bucket. Additionally, improper functioning of the ice maker leads to service calls and unhappy customers.

To address the above identified problems, installers and/or repair servicemen typically shim the ice maker to level the ice maker with respect to the ice bucket. However, the shimming process is inaccurate and may be temporary. Additionally, installers and/or repair servicemen adjust the position of the feeler arm by physically moving or adjusting the feeler arm. However, such manipulation of the feeler arm may lead to permanent damage to the feeler arm.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, an ice maker for a refrigerator is provided. The refrigerator includes a freezer compartment having a top wall, side walls, a back wall, and a door opposite the back wall. The ice maker includes a mold body having at least one cavity for containing water therein for freezing into ice, and a control housing extending from the mold body. The control housing is configured to be coupled to a mounting surface of said freezer compartment, wherein the mounting surface includes at least one of the top wall, the side walls, the back wall, and the door of the freezer compartment.

In another aspect, an ice maker for a refrigerator is provided. The refrigerator includes a freezer compartment having a top wall, side walls, a back wall, and a door opposite the back wall. The ice maker includes a mold body having at least one cavity for containing water therein for freezing into ice, an ice removal element operationally coupled to the mold body, and a motor operationally coupled to the ice removal element. A control housing extends from the mold body and houses the motor. An end cover is coupled to the control housing, and the end cover is configured to be mounted to a mounting surface of the freezer compartment, wherein the mounting surface includes at least one of the top wall, one of the side walls, the back wall, and the door of the freezer compartment.

In a further aspect, a method of mounting an ice maker within a freezer compartment of a refrigerator is provided. The freezer compartment includes a top wall, side walls, a back wall, and a door opposite the back wall. The method includes providing a mold body having at least one cavity for containing water therein for freezing into ice, providing a control housing, wherein the control housing extends from the mold body, and coupling the control housing to a mounting surface of the freezer compartment, wherein the mounting surface includes at least one of the top wall, one of the side walls, the back wall, and the door of the freezer compartment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a side-by-side refrigerator.

FIG. 2 illustrates a front view of the refrigerator shown in FIG. 1.

FIG. 3 is a cross sectional view of an exemplary ice-maker for the refrigerator shown in FIG. 1.

FIG. 4 is a perspective view of the ice maker shown in FIG. 3.

FIG. 5 illustrates the ice-maker shown in FIG. 3 mounted within a freezer compartment of the refrigerator shown in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates an exemplary refrigerator 100. While the apparatus is described herein in the context of a specific refrigerator 100, it is contemplated that the herein described methods and apparatus may be practiced in other types of refrigerators. Therefore, as the benefits of the herein described methods and apparatus accrue generally to ice maker mounting methods and apparatus in a variety of refrigeration appliances and machines, the description herein is for exemplary purposes only and is not intended to limit practice of the invention to a particular refrigeration appliance or machine, such as refrigerator 100.

Refrigerator 100 includes a fresh food storage compartment 102 and freezer storage compartment 104. Freezer compartment 104 and fresh food compartment 102 are arranged side-by-side, however, the benefits of the herein described methods and apparatus accrue to other configurations such as, for example, top and bottom mount refrigerator-freezers. Refrigerator 100 includes an outer case 106 and inner liners 108 and 110. A space between case 106 and liners 108 and 110, and between liners 108 and 110, is filled with foamed-in-place insulation. Outer case 106 normally is formed by folding a sheet of a suitable material, such as pre-painted steel, into an inverted U-shape to form top and side walls of case. A bottom wall of case 106 normally is formed separately and attached to the case side walls and to a bottom frame that provides support for refrigerator 100. Inner liners 108 and 110 are molded from a suitable plastic material to form freezer compartment 104 and fresh food compartment 102, respectively. Alternatively, liners 108, 110 may be formed by bending and welding a sheet of a suitable metal, such as steel. The illustrative embodiment includes two separate liners 108, 110 as it is a relatively large capacity unit and separate liners add strength and are easier to maintain within manufacturing tolerances. In smaller refrigerators, a single liner is formed and a mullion spans between opposite sides of the liner to divide it into a freezer compartment and a fresh food compartment.

A breaker strip 112 extends between a case front flange and outer front edges of liners 108 and 110. Breaker strip 112 is formed from a suitable resilient material, such as an extruded acrylo-butadiene-styrene based material (commonly referred to as ABS).

The insulation in the space between liners 108, 110 is covered by another strip of suitable resilient material, which also commonly is referred to as a mullion 114. Mullion 114 also, in one embodiment, is formed of an extruded ABS material. Breaker strip 112 and mullion 114 form a front face, and extend completely around inner peripheral edges of case 106 and vertically between liners 108, 110. Mullion 114, insulation between compartments, and a spaced wall of liners separating compartments, sometimes are collectively referred to herein as a center mullion wall 116.

In the exemplary embodiment, freezer compartment 104 is defined by a top wall 118, a bottom wall 120, a back wall 122, a first side wall 124, and a second side wall 126. Top wall 118, bottom wall 120, back wall 122 and first side wall 124 are each formed by inner liner 110. Second side wall 126 is formed by mullion 114. Alternatively, second side wall 126 is formed by inner liner 110. Shelves and baskets are provided in freezer compartment 104 and extend between first and second side walls 124 and 126, respectively. In addition, a storage bin or ice bucket 128 and an ice maker 130 are provided in freezer compartment 104. In the exemplary embodiment, ice maker 130 is coupled to first side wall 124 and extends centrally into freezer compartment 104 over storage bin 128. In alternative embodiments, ice maker 130 is coupled to one of top wall 118, back wall 122, second side wall 126, or a freezer door 132.

Freezer door 132 and a fresh food door 134 close access openings to fresh food and freezer compartments 102, 104, respectively. Each door 132, 134 is mounted by a top hinge 136 and a bottom hinge (not shown) to rotate about its outer vertical edge between an open position, as shown in FIG. 1, and a closed position (shown in FIG. 2) closing the associated storage compartment. Freezer door 132 includes a plurality of storage shelves 138 and a sealing gasket 140, and fresh food door 134 also includes a plurality of storage shelves 142 and a sealing gasket 144.

FIG. 2 is a front view of refrigerator 100 with doors 134 and 132 in a closed position. Freezer door 132 includes a through the door dispenser 146, and a user interface 148. Dispenser 146 is configured to dispense water supplied from a water source (not shown). Dispenser 146 is also configured to dispense ice produced by ice maker 130 (shown in FIG. 1), such as through an ice chute (not shown) in freezer door 132. User interface 148 is used to change the dispensing mode between water and ice dispensing.

FIG. 3 is a cross sectional view of ice maker 130 including a metal mold body 150 with a tray structure having a bottom wall 152, a front wall 154, and a back wall 156. A plurality of partition walls 158 extend transversely across mold body 150 to define cavities in which ice pieces 160 are formed. Each partition wall 158 includes a recessed upper edge portion 162 through which water flows successively through each cavity to fill mold body 150 with water.

Ice maker 130 is mounted within freezer compartment 104 to first side wall 124 proximate top wall 118 and back wall 122. Ice maker 130 extends generally parallel to back wall 122. In the exemplary embodiment, ice maker 130 is mounted such that an air gap 163 is provided between ice maker 130 and back wall 122 to allow circulation of air between ice maker 130 and back wall 122. Additionally, in the exemplary embodiment, no portion of ice maker 130 or other structures or components extend between ice maker 130 and back wall 122. Ice maker 130 is not supported by back wall 122.

A sheathed electrical resistance ice removal heating element or heater 164 is press-fit, staked, and/or clamped into bottom wall 152 of mold body 150 and heats mold body 150 when a harvest cycle is executed to slightly melt ice pieces 160 and release them from the mold cavities. An ice removal element or rotating rake 166 sweeps through mold body 150 as ice is harvested and ejects ice from mold body 150 into storage bin 128. Cyclical operation of heater 164 and rake 166 are effected by a controller 170 disposed within a control housing 172 at a mounting end 174 of mold body 150. For example, controller 170 is operatively coupled to a motor 176 for turning or rotating rake 166 during a harvest cycle. Controller 170 is also operatively coupled to heater 164 for heating mold body 150 during a harvest cycle. Additionally, controller 170 is operatively coupled to a water valve (not shown) to automatically provides for refilling mold body 150 with water for ice formation after ice is harvested. The water valve is connected to a water line (not shown) that receives water from a water source (not shown), and delivers water to mold body 150 through an inlet structure (not shown). The water fills successive cavities of mold body 150 with water through recessed upper edge portions 162.

In order to sense a level of ice pieces 160 in storage bin 128, controller 170 actuates a spring loaded feeler arm 178 for controlling an automatic ice harvest so as to maintain a selected level of ice in storage bin 128. Feeler arm 178 is automatically raised and lowered during operation of ice maker 130 as ice is formed. Feeler arm 178 is spring biased to a lowered home position that is used to determine initiation of a harvest cycle and raised by a mechanism (not shown) as ice is harvested to clear ice entry into storage bin 128 and to prevent accumulation of ice above feeler arm 178 so that feeler arm 178 does not move ice out of storage bin 128 as feeler arm 178 raises. When ice obstructs feeler arm 178 from reaching its home position, controller 170 discontinues harvesting because storage bin 128 is sufficiently full. As ice is removed from storage bin 128, feeler arm 178 gradually moves to its home position, thereby indicating a need for more ice and causing controller 170 to initiate formation and harvesting of ice pieces 160.

In another exemplary embodiment, a cam-driven feeler arm (not shown) rotates underneath ice maker 130 and out over storage bin 128 as ice is formed. Feeler arm 178 is spring biased to an outward or home position that is used to initiate an ice harvest cycle, and is rotated inward and underneath ice maker 130 by a cam slide mechanism (not shown) as ice is harvested from ice maker mold body 150 so that the feeler arm does not obstruct ice from entering storage bin 128 and to prevent accumulation of ice above the feeler arm. After ice is harvested, the feeler arm is rotated outward from underneath ice maker 130, and when ice obstructs the feeler arm and prevents the feeler arm from reaching the home position, controller 170 discontinues harvesting because storage bin 128 is sufficiently full. As ice is removed from storage bin 128, feeler arm 178 gradually moves to its home position, thereby indicating a need for more ice and causing controller 170 to initiate formation and harvesting of ice pieces 160.

FIG. 4 is a perspective view of ice maker 130 illustrating mold body 150 and control housing 172. Mold body 150 includes an open top 180 extending between mounting end 174 and a free end 182 of mold body 150. Mold body 150 also includes a front face 184 and a rear face 186. Front face 184 is substantially aligned with storage bin 128 (shown in FIG. 1) when ice maker 130 is mounted within freezer compartment 104 such that ice pieces 160 are dispensed from mold body 150 at front face 184 into storage bin 128. Rear face 186 faces back wall 122 of freezer compartment 104 (shown in FIG. 1). In one embodiment, brackets 188 extend upward from rear face 186.

Rake 166 extends from control housing 172 along top 180 of mold body 150. Rake 166 includes individual fingers 190 received within each of the cavities of mold body 150. In operation, rake 166 is rotated about an axis of rotation or rake axis 192 that extends generally parallel to front face 184 and rear face 186. As described above, motor 176 (shown in FIG. 3) is housed within control housing 172 and is used for turning or rotating rake 166 about axis of rotation 192.

In the exemplary embodiment, control housing 172 is provided at mounting end 174 of mold body 150. Control housing 172 includes a housing body 200 and an end cover 202 attached to housing body 200. Housing body 200 extends between a first end 204 and a second end 206. First end 204 is secured to mounting end 174 of mold body 150. Alternatively, housing body 200 and mold body 150 are integrally formed. Housing body 200 houses motor 176 and controller 170 (shown in FIG. 3). End cover 202 is coupled to second end 206 of housing body 200 and closes access to housing body 200. In an alternative embodiment, end cover 202 is integrally formed with housing body 200.

In the exemplary embodiment, end cover 202 is used for mounting ice maker 130 within freezer compartment 104. End cover 202 includes a rear end 210, a forward end 212, a top end 214, a bottom end 216, and an end cover mounting surface 218. In the exemplary embodiment, end cover 202 includes mounting slots 220 open to rear end 210 and end cover mounting surface 218. Alternatively, mounting slots 220 are open to top end 214 to facilitate mounting to top wall 118 (shown in FIG. 1) of freezer compartment 104. Mounting slots 220 are configured to receive a fastening element (not shown) to support ice maker 130 during installation of ice maker 130. Forward end 212 includes an extension 222 extending beyond an envelope of housing body 200. Protrusion includes a fastener bore 224 configured to receive a fastener (not shown), such as, for example, a screw, a rivet, a pin or the like during installation of ice maker 130.

FIG. 5 illustrates ice maker 130 mounted within freezer compartment 104 of refrigerator 100. Ice maker 130 is mounted within freezer compartment 104 to first side wall 124 proximate top wall 118 and back wall 122. First side wall 124 thus defines a mounting surface for ice maker 130. Ice maker 130 extends generally parallel to back wall 122 and top wall 118, and extends perpendicularly outward from first side wall 124. Specifically, a mold body axis 228 that extends generally across the multiple cavities of mold body 150 extends generally parallel to back wall 122 and top wall 118. Ice maker 130 is generally forward facing such that front face 184 of mold body 150 is open to or faces the opening of freezer compartment 104. Additionally, ice maker 130 may be centrally positioned with respect to the front and back of freezer compartment 104, as ice maker is mounted to first side wall 124 and is not mounted to back wall 122.

During installation or mounting of ice maker 130 within freezer compartment 104, ice maker 130 is provided. For example, control housing 172 is coupled to mold body 150. End cover 202 is coupled to housing body 200. Prior to mounting, fastener elements 230 are secured to first side wall 124 of freezer compartment 104. In the exemplary embodiment, fastener elements 230 include a grommet secured to first side wall 124 by a screw. During installation, end cover mounting surface 218 is positioned proximate the mounting surface of freezer compartment 104 and a portion of fastener elements 230 are received in mounting slots 220 (shown in FIG. 4) of end cover 202. For example, mounting slots 220 are aligned with fastener elements 230 and ice maker 130 is slid generally toward back wall 122 of freezer compartment 104. Fastener elements 230 support ice maker 130 and resist movement of ice maker 130 in a downward direction generally away from top wall 118. A fastener 232 is then used to secure ice maker 130 in the installed position. Fastener 232 is driven through fastener bore 224 (shown in FIG. 4). Fastener 232 resists movement of ice maker 130 in both a vertical direction, such as in a direction away from top wall 118, and a horizontal direction, such as in a direction generally away from back wall 122 or in a direction generally away from first side wall 124.

Methods and apparatus for mounting an ice maker are thus provided which mount the ice maker in a cost effective and reliable manner. Manufacturing, assembling, and installation costs are reduced due to a reduced component number and cost. Additionally, the end cover and associated mounting components may be retro-fit to existing ice makers. In addition, reliable and accurate installation is achieved for accurate ice level detection and improved thermal efficiency.

Exemplary embodiments of an ice maker are described above in detail. Each ice maker is not limited to the specific embodiments described herein, but rather each component may be utilized independently and separately from other components described herein. Each component can also be used in combination with other ice makers.

While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.

Claims

1. An ice maker for a refrigerator, wherein the refrigerator includes a freezer compartment having a top wall, side walls, a back wall, and a door opposite the back wall, said ice maker comprising:

a mold body comprising at least one cavity for containing water therein for freezing into ice; and

a control housing extending from said mold body, said control housing configured to be coupled to a mounting surface of said freezer compartment, wherein the mounting surface includes at least one of the top wall, the side walls, the back wall, and the door of the freezer compartment.

2. An ice maker in accordance with claim 1 wherein said control housing configured to be mounted to one of the side walls such that an air gap is formed between said mold body and the back wall.

3. An ice maker in accordance with claim 1 wherein said mold body comprises multiple cavities aligned along a mold body axis, said mold body axis extending substantially parallel to the back wall of the freezer compartment.

4. An ice maker in accordance with claim 1 wherein said mold body includes a front face, the ice is removed from said cavities at said front face, said control housing extending substantially perpendicular to said front face.

5. An ice maker in accordance with claim 1 wherein said control housing comprises a mounting slot, said ice maker further comprising a fastening element configured to be mounted to the mounting surface, said fastening element received in said mounting slot when said control housing mounted to the mounting surface.

6. An ice maker for a refrigerator, wherein the refrigerator includes a freezer compartment having a top wall, side walls, a back wall, and a door opposite the back wall, said ice maker comprising:

a mold body comprising at least one cavity for containing water therein for freezing into ice;

an ice removal element operationally coupled to said mold body;

a motor operationally coupled to said ice removal element;

a control housing extending from said mold body and housing said motor; and

an end cover coupled to said control housing, said end cover configured to be mounted to a mounting surface of the freezer compartment, wherein the mounting surface includes at least one of the top wall, one of the side walls, the back wall, and the door of the freezer compartment.

7. An ice maker in accordance with claim 6 wherein said end cover configured to be mounted a distance from the back wall of the freezer compartment.

8. An ice maker in accordance with claim 6 wherein said end cover configured to be mounted such that an air gap surrounds said mold body.

9. An ice maker in accordance with claim 6 wherein said end cover configured for bracketless mounting.

10. An ice maker in accordance with claim 6 wherein said end cover configured to directly mount to the mounting surface.

11. An ice maker in accordance with claim 6 wherein said mold body comprises multiple cavities aligned along a mold body axis, said mold body axis extending substantially parallel to the back wall of the freezer compartment.

12. An ice maker in accordance with claim 6 wherein said ice removal element comprises a rake extending from said control housing along a rake axis, said rake axis extending substantially parallel to the back wall of the freezer compartment.

13. An ice maker in accordance with claim 6 wherein said motor configured to rotate said ice removal element along an axis of rotation, said axis of rotation extending substantially parallel to the back wall of the freezer compartment.

14. An ice maker in accordance with claim 6 wherein said mold body includes a front face, the ice is removed from said cavities at said front face, said end cover extending substantially perpendicular to said front face.

15. An ice maker in accordance with claim 6 wherein said end cover comprises a mounting slot, said ice maker further comprising a fastening element configured to be mounted to the mounting surface, said fastening element received in said mounting slot when said end cover mounted to the mounting surface.

16. A method of mounting an ice maker within a freezer compartment of a refrigerator, wherein the freezer compartment includes a top wall, side walls, a back wall, and a door opposite the back wall, said method comprising:

providing a mold body having at least one cavity for containing water therein for freezing into ice;

providing a control housing, wherein the control housing extends from the mold body; and

coupling the control housing to a mounting surface of the freezer compartment, wherein the mounting surface includes at least one of the top wall, one of the side walls, the back wall, and the door of the freezer compartment.

17. A method in accordance with claim 16 wherein the mold body includes multiple cavities aligned along a mold body axis, said coupling the control housing to a mounting surface comprises coupling the control housing to a mounting surface such that the mold body axis extends substantially parallel to the back wall of the freezer compartment.

18. A method in accordance with claim 16 wherein the mold body includes a front face, the ice is removed from the cavities at the front face, said providing a control housing comprises providing a control housing having an end cover that extends substantially perpendicular to the front face, said coupling the control housing to a mounting surface comprises coupling the end cover to the mounting surface.

19. A method in accordance with claim 16 further comprising:

providing a motor within the control housing;

providing an ice removal element;

coupling the motor to the ice removal element wherein the motor being configured to rotate the ice removal element along an axis of rotation, the axis of rotation extends substantially parallel to the back wall of the freezer compartment.

20. A method in accordance with claim 16 wherein the control housing includes a mounting slot, said method further comprises:

coupling a fastening element to the mounting surface; and

coupling the mounting slot to the fastening element.