CLEAR ICE MAKER AND METHOD FOR FORMING CLEAR ICE
An ice maker, including sensors to measure usage parameters and transmit the same to a controller. The controller is operably connected to a plurality of ice forming systems, and directs the systems to operate in a high energy mode or a low energy mode, based on the usage parameter. The usage parameters may include an ice level, a change in the ice level over time, the amount of time that a dispenser is actuated, the time of day, or historical usage patterns. The ice forming systems may include one or more of a thermoelectric device coupled to a bottom surface of an ice forming plate, a forced air system to circulate cold air, a forced air system to circulate warm air, and a temperature control system to maintain a temperature gradient between a first chamber above the ice forming plate and a second chamber below the ice forming plate.
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The present application is related to, and hereby incorporates by reference the entire disclosures of, the following applications for United States Patents: U.S. patent application Ser. No. ______, entitled “Ice Maker with Rocking Cold Plate,” filed on even date herewith (attorney docket no. SUB-01625-US-NP); U.S. patent application Ser. No. ______, entitled “Clear Ice Maker with Warm Air Flow,” filed on even date herewith (attorney docket no. SUB-01518-US-NP); U.S. patent application Ser. No. ______, entitled “Clear Ice Maker with Varied Thermal Conductivity,” filed on even date herewith (attorney docket no. PAT-00123-US-NP); U.S. patent application Ser. No. ______, entitled “Clear Ice Maker,” filed on even date herewith (attorney docket no. SUB-02962-US-NP); U.S. patent application Ser. No. ______, entitled “Layering of Low Thermal Conductive Material on Metal Tray,” filed on even date herewith (attorney docket no. SUB-02939-US-NP); U.S. patent application Ser. No. ______, entitled “Clear Ice Maker,” filed on even date herewith (attorney docket no. SUB-02960-US-NP); U.S. patent application Ser. No. ______, entitled “Twist Harvest Ice Geometry,” filed on even date herewith (attorney docket no. SUB-02946-US-NP); U.S. patent application Ser. No. ______, entitled “Cooling System for Ice Maker,” filed on even date herewith (attorney docket no. SUB-03712-US-NP); U.S. patent application Ser. No. ______, entitled “Clear Ice Maker and Method for Forming Clear Ice,” filed on even date herewith (attorney docket no. SUB-02940-US-NP); and U.S. patent application Ser. No. ______, entitled “Clear Ice Maker and Method for Forming Clear Ice,” filed on even date herewith (attorney docket no. SUB-02973-US-NP).
FIELD OF THE INVENTIONThe present invention generally relates to an ice maker for making substantially clear ice pieces, and methods for the production of clear ice pieces. More specifically, the present invention generally relates to an ice maker and methods which are capable of making substantially clear ice without the use of a drain.
BACKGROUND OF THE INVENTIONDuring the ice making process when water is frozen to form ice cubes, trapped air tends to make the resulting ice cubes cloudy in appearance. The trapped air results in an ice cube which, when used in drinks, can provide an undesirable taste and appearance which distracts from the enjoyment of a beverage. Clear ice requires processing techniques and structure which can be costly to include in consumer refrigerators and other appliances. There have been several attempts to manufacture clear ice by agitating the ice cube trays during the freezing process to allow entrapped gases in the water to escape.
SUMMARY OF THE INVENTIONIn one aspect, the present invention includes an adaptive ice maker for making clear ice pieces, including a sensor which detects a usage parameter of the ice maker and transmits the usage parameter to a controller. The controller is operably connected to a plurality of ice forming systems, and the controller directs the ice forming systems to operate in a high energy mode or in a low energy mode, based on the usage parameter.
In another aspect of the present invention, an adaptive ice maker for making clear ice pieces includes a sensor to detect a usage parameter of the ice maker and transmit the usage parameter to a controller, wherein the controller is operably connected to a plurality of ice forming systems and is operable to direct the ice forming systems to operate in a first energy mode, a second energy mode, or a third energy mode, wherein the first energy mode requires more energy than the second energy mode, and the second energy mode requires more energy than the third energy mode.
In a further aspect of the present invention, a method of forming ice includes the step of measuring ice usage parameters and determining whether to operate a plurality of ice forming systems of an ice maker in a high energy mode or a low energy mode, based on the usage parameters.
These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.
In the drawings:
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivates thereof shall relate to the ice maker assembly 52, 210 as oriented in
Referring initially to
The ice maker housing 54 communicates with an ice cube storage container 64, which, in turn, communicates with an ice dispenser 66 such that ice 98 can be dispensed or otherwise removed from the appliance with the door 56 in the closed position. The dispenser 66 is typically user activated.
In one aspect, the ice maker 52 of the present invention employs varied thermal input to produce clear ice pieces 98 for dispensing. In another aspect the ice maker of the present invention employs a rocking motion to produce clear ice pieces 98 for dispensing. In another, the ice maker 52 uses materials of construction with varying conductivities to produce clear ice pieces for dispensing. In another aspect, the icemaker 52 of the present invention is a twist-harvest ice maker 52. Any one of the above aspects, or any combination thereof, as described herein may be used to promote the formation of clear ice. Moreover, any aspect of the elements of the present invention described herein may be used with other embodiments of the present invention described, unless clearly indicated otherwise.
In general, as shown in
In certain embodiments, multiple steps may occur simultaneously. For example, the ice forming plate 76 may be cooled and rocked while the water is being dispensed onto the ice forming plate 76. However, in other embodiments, the ice forming plate 76 may be held stationary while water is dispensed, and rocked only after an initial layer of ice 98 has formed on the ice forming plate 76. Allowing an initial layer of ice to form prior to initiating a rocking movement prevents flash freezing of the ice or formation of a slurry, which improves ice clarity.
In one aspect of the invention, as shown in
In the embodiment depicted in
A grid 100 is provided, as shown in
As shown in
As shown in FIGS. 5 and 7A-7F, in one aspect the ice tray 70 is supported by and pivotally coupled to a rocker frame 110, with an oscillating motor 112 operably connected to the rocker frame 110 and ice tray 70 at one end 138, and a harvest motor 114 operably connected to the ice tray 70 at a second end 142.
The rocker frame 110 is operably coupled to an oscillating motor 112, which rocks the frame 110 in a back and forth motion, as illustrated in
Having briefly described the overall components and their orientation in the embodiment depicted in
The rocker frame 110 in the embodiment depicted in
As shown in
The ice tray 70 includes an integral axle 134 which is coupled to a drive shaft 136 of the oscillating motor 112 for supporting a first end of the ice tray 138. The ice tray 70 also includes a second pivot axle 140 at an opposing end 142 of the ice tray 70, which is rotatably coupled to the rocker frame 110.
The grid 100, which is removable from the ice forming plate 76 and containment wall 82, includes a first end 144 and a second end 146, opposite the first end 144. Where the containment wall 82 diverges from the ice freezing plate 76 and then extends vertically upward, the grid 100 may have a height which corresponds to the portion of the containment wall 82 which diverges from the ice freezing plate 76. As shown in
The containment wall 82 includes a socket 152 at its upper edge for receiving the pivot axle 148 of the grid 100. An arm 154 is coupled to a drive shaft 126 of the harvest motor 114, and includes a slot 158 for receiving the cam pin 150 formed on the grid 100.
A torsion spring 128 typically surrounds the internal axle 134 of the containment wall 82, and extends between the arm 154 and the containment wall 82 to bias the containment wall 82 and ice forming plate 76 in a horizontal position, such that the cam pin 150 of the grid 100 is biased in a position of the slot 158 of the arm 154 toward the ice forming plate 76. In this position, the grid 100 mates with the top surface 78 of the ice forming plate 76 in a closely adjacent relationship to form individual compartments 96 that have the ice forming plate defining the bottom and the grid defining the sides of the individual ice forming compartments 96, as seen in
The grid 100 includes an array of individual compartments 96, defined by the median wall 84, the edge walls 95 and the dividing walls 94. The compartments 96 are generally square in the embodiment depicted in
As shown in
The ice maker 52 is positioned over an ice storage bin 64. Typically, an ice bin level detecting arm 164 extends over the top of the ice storage bin 64, such that when the ice storage bin 64 is full, the arm 164 is engaged and will turn off the ice maker 52 until such time as additional ice 98 is needed to fill the ice storage bin 64.
As the water cascades over the median wall 84, air in the water is released, reducing the number of bubbles in the clear ice piece 98 formed. The rocking may also be configured to expose at least a portion of the top layer of the clear ice pieces 98 as the liquid water cascades to one side and then the other over the median wall 84, exposing the top surface of the ice pieces 98 to air above the ice tray. The water is also frozen in layers from the bottom (beginning adjacent the top surface 78 of the ice forming plate 76, which is cooled by the thermoelectric device 102) to the top, which permits air bubbles to escape as the ice is formed layer by layer, resulting in a clear ice piece 98.
As shown in
As shown in
Alternatively, the heat may be applied by a heating element (not shown) configured to supply heat to the interior volume 168 of the housing 54 above the ice tray 70. Applying heat from the top also encourages the formation of clear ice pieces 98 from the bottom up. The heat application may be deactivated when ice begins to form proximate the upper portion of the grid 100, so that the top portion of the clear ice pieces 98 freezes.
Additionally, as shown in
As shown in
As shown in
Once the clear ice pieces 98 have been dumped into the ice storage bin 64, the harvest motor 114 is reversed in direction, returning the ice tray 7 to a horizontal position within the rocker frame 110, which has remained in the neutral position throughout the turning of the harvest motor 114. Once returned to the horizontal starting position, an additional amount of water can be dispensed into the ice tray 70 to form an additional batch of clear ice pieces.
The control circuit 198 includes a microprocessor 204 which receives temperature signals from the ice maker 52 in a conventional manner by one or more thermal sensors (not shown) positioned within the ice maker 52 and operably coupled to the control circuit 198. The microprocessor 204 is programmed to control the water dispensing valve 200, the oscillating motor 112, and the thermoelectric device 114 such that the arc of rotation of the ice tray 70 and the frequency of rotation is controlled to assure that water is transferred from one individual compartment 96 to an adjacent compartment 96 throughout the freezing process at a speed which is harmonically related to the motion of the water in the freezer compartments 96.
The water dispensing valve 200 is actuated by the control circuit 198 to add a predetermined amount of water to the ice tray 70, such that the ice tray 70 is filled to a specified level. This can be accomplished by controlling either the period of time that the valve 200 is opened to a predetermined flow rate or by providing a flow meter to measure the amount of water dispensed.
The controller 198 directs the frequency of oscillation ω to a frequency which is harmonically related to the motion of the water in the compartments 96, and preferably which is substantially equal to the natural frequency of the motion of the water in the trays 70, which in one embodiment was about 0.4 to 0.5 cycles per second. The rotational speed of the oscillating motor 112 is inversely related to the width of the individual compartments 96, as the width of the compartments 96 influences the motion of the water from one compartment to the adjacent compartment. Therefore, adjustments to the width of the ice tray 70 or the number or size of compartments 96 may require an adjustment of the oscillating motor 112 to a new frequency of oscillation w.
The waveform diagram of
After the freezing process, the voltage supplied to the thermoelectric device 102 may optionally be reversed, to heat the ice forming plate 76 to a temperature above freezing, freeing the clear ice pieces 98 from the top surface 78 of the ice forming plate 76 by melting a portion of the clear ice piece 98 immediately adjacent the top surface 78 of the ice forming plate 76. This allows for easier harvesting of the clear ice pieces 98. In the embodiment described herein and depicted in
In another aspect of the ice maker 210, as shown in
The ice maker 210 depicted in
As shown in
The ice tray 218 and thermoelectric device 238 are typically disposed within a shroud member 250 having a generally cylindrical shape aligned with the transverse axis of the ice tray 218. The shroud member 250 is typically an incomplete cylinder, and is open over the top of the ice tray 218. The shroud 250 includes at least partially closed end walls 252 surrounding the first end 246 of the ice tray 218 and a second end 248 of the ice tray 218. The shroud member 250 typically abuts the periphery of the containment wall 226 to separate a first air chamber 254 above the ice tray 218 and a second air chamber 256 below the ice tray 218. The housing 212 further defines the first air chamber 254 above the ice tray 218.
As illustrated in
As shown in
Also as shown in
During ice freezing, the harvest motor 244 is maintained in a locked position, such that the keyed drive shaft 274 of the harvest motor 244, which is linked to the ice tray 218, rotates the ice tray 218 in the same arc that the frame member 292 is rotated by the oscillation motor 242. As described above, an arc from about 20° to about 40°, and preferably about 30°, is preferred for the oscillation of the ice tray 218 during the ice freezing step. During the harvest step, as further described below, the oscillating motor 242 is stationary, as is the frame member 292. The harvest motor 244 rotates its keyed drive shaft 274, which causes the ice tray 218 to be inverted and the ice 236 to be expelled.
It is believed that a single motor could be used in place of the oscillating motor 242 and harvest motor 244 with appropriate gearing and/or actuating mechanisms.
An ice bin level sensor 30 is also provided, which detects the level of ice 236 in the ice storage bin (not shown in
To facilitate air movement, as shown in
As shown in
The ice tray 218 is also shown in detail in
The arrangement of the grid 232, and the materials of construction for the grid 232 as described herein facilitate the “twist release” capability of the ice tray 218. The features described below allow the grid 232 to be rotated at least partially out of the containment wall 226, and to be twisted, thereby causing the clear ice pieces 236 to be expelled from the grid 232. As shown in
The thermoelectric device 102, as depicted in the embodiment shown in
The second end 248 of the containment wall 226 and shroud 250 (the side away from the motors 242, 244) are shown in
As shown in
When installed in the housing 212, the shroud member 250 is configured to maintain contact with the barrier 354 as the ice tray 218 is oscillated during ice formation. An air intake duct member 356 having a duct inlet 358 and a duct outlet 360, with the duct outlet 360 adapted to fit over the surface of the shroud 250 and maintain contact with the shroud 250 as the shroud 250 rotates, is also fitted into the housing 212. The shaped opening of the duct outlet 260 is sufficiently sized to allow a fluid connection between the duct outlet 260 and the first rectangular slot 312 even as the ice tray 218 and shroud 250 are reciprocally rotated during the freezing cycle. The rectangular slot 312 restricts the amount of air 356 entering the shroud 250, such that the amount of air 370 remains constant even as the ice tray 218 is rotated. An exhaust duct 362 is optionally provided adjacent the second rectangular opening 314, to allow air 370 to escape the housing 212. The exhaust duct 362 has a duct intake 364 which is arranged to allow continuous fluid contact with the second rectangular slot 314 as the ice tray 218 and shroud 250 are rocked during the ice formation stage. The exhaust duct 362 also has a duct outlet 366 which is sufficiently sized to allow the clear ice pieces 236 to fall through the duct outlet 366 and into the ice bin 64 during the harvesting step.
An air flow path 368 is created that permits cold air 370 to travel from the duct inlet 358, to the duct outlet 360, into the first rectangular slot 312 in the shroud, across the heat sink fins 344, which are preferably a conductive metallic material, and out of the second rectangular slot 314 in the shroud 250 into the exhaust duct 362. As shown in
One example of an air flow path 368 enabled by the air intake duct 356 and exhaust duct 362 is shown in
In general, the ice makers 52, 210 described herein create clear ice pieces 98, 236 through the formation of ice in a bottom-up manner, and by preventing the capture of air bubbles or facilitating their release from the water. The clear ice pieces 98, 236 are formed in a bottom-up manner by cooling the ice tray 70, 218 from the bottom, with or without the additional benefit of cold air flow to remove heat from the heat sink 104, 318. The use of insulative materials to form the grid 100, 232 and containment walls 82, 226, such that the cold temperature of the ice forming plate 76, 220 is not transmitted upward through the individual compartments 96, 234 for forming ice also aids in freezing the bottom layer of ice first. A warm air flow over the top of the clear ice pieces 98, 236 as they are forming can also facilitate the unidirectional freezing. Rocking aids in the formation of clear ice pieces 98, 236 in that it causes the release of air bubbles from the liquid as the liquid cascades over the median wall 84, 228, and also in that it encourages the formation of ice in successive thin layers, and, when used in connection with warm air flow, allows exposure of the surface of the clear ice piece 98, 236 to the warmer temperature.
The ice makers described herein also include features permitting the harvest of clear ice pieces 98, 236, including the harvest motor 114, 244, which at least partially inverts the ice tray 70, 218, and then causes the release and twisting of the grid 100, 232 at least partially out of the containment wall 84, 226 to expel clear ice pieces 98, 236. The ice forming plate 76, 220 and associated thermoelectric device 102, 238 can also be used to further facilitate harvest of clear ice pieces 98, 236 by reversing polarity to heat the ice forming plate 76, 220 and, therefore, heat the very bottom portion of the clear ice pieces 98, 236 such that the clear ice pieces 98, 236 are easily released from the ice forming plate 76, 220 and removed from contacting the ice forming plate 76, 220.
As shown in
As shown in
The ice forming plate 404 is preferably formed of a thermally conductive material such as a metallic material, and the insulating layer 418 is preferably an insulator such as a polymeric material. One non-limiting example of a polymeric material suitable for use as an insulator is a polypropylene material. The insulating layer 418 may be adhered to the ice forming plate 404, molded onto the ice forming plate 404, mechanically engaged with the ice forming plate 404, overlayed over the plate 404 without attaching, or secured in other removable or non-removable ways to the ice forming plate 404. The insulating layer 418 may also be an integral portion of the ice forming plate 76 material. This construction, using an insulating layer 418 proximate the top of the ice wells 406, facilitates freezing of the clear ice piece 98 from the top surface 78 of the ice forming plate 76 upward.
An evaporator element 420 is thermally coupled with the ice forming plate 404, typically along the outside of the ice wells 406, opposite the ice forming compartments 416, and the evaporator element 420 extends along a transverse axis 422 of the ice forming plate 404. The evaporator element 420 includes a first coil 424 proximate a first end 426 of the ice forming plate 404 and a second coil 428 proximate the second end 403 of the ice forming plate 404.
The ice forming plate 404 and insulating layer 418 as shown in
In addition to the multiple configurations described above, as shown in
The sensor 444 may detect, for example, the level of ice 98 in an ice bin 64, the change in the level of ice 98 in the bin 64 over time, the amount of time that a dispenser 66 has been actuated by a user, and/or when the dispenser has been actuated to determine high and low ice usage time periods. This information 442 is typically transmitted to the controller 440, which uses the information 442 to determine whether and when to operate the ice maker 52 in a high energy mode or a low energy mode based upon usage parameters or timer periods of usage. This allows the ice maker 52 to dynamically adjust its output based on usage patterns over time, and if certain data are collected, such as the time of day when the most ice 98 is used, the ice maker 52 could operate predictively, producing more ice 98 prior to the heavy usage period. Operating the ice maker 52 in a high energy mode would result in the faster production of ice 98, but would generally be less efficient than the low energy mode. Operating in the high energy mode would typically be done during peak ice usage times, while low energy mode would be used during low usage time periods. An ice maker 52 having three or more energy modes of varying efficiencies may also be provided, with the controller 440 able to select an energy mode from among the three or more energy modes.
One example of an ice maker 52 which could be operated by such a controller 440 would be an ice maker 52 having a plurality of systems 452 which operate to aid in the formation of clear ice pieces 98, including an oscillating system as described above, a thermoelectric cooling system as described above, a forced air system to circulate warm air as described above, a forced air system to circulate cold air as described above, a forced air system to circulate warm air as described above, a housing 54 which is split into a first air chamber 254 and a second air chamber 256 with a temperature gradient therebetween as described above, and a thermoelectric heating system (to aid in harvesting clear ice pieces) as described above.
Operating an ice maker 52 in a high energy mode could include, for example, the use of a particular oscillation setting, a thermoelectric device setting, one or more air circulator settings for use during the ice freezing process, wherein the settings in the high energy mode require more energy, and result in the faster formation of clear ice pieces 98. The high energy mode could also include using the thermoelectric device 102 to provide a higher temperature to the ice forming plate 76 to cause a faster release of ice pieces 98 during the harvest process and to shorten cycle time for filling and making the ice pieces.
The low energy mode could also include a delay in dispensing water into the ice tray, or a delay in harvesting the clear ice pieces 98 from the ice tray 70 as well as lower electronic power (energy) use by the motors 112, 114 and thermoelectric devices 102 than the normal mode or high energy mode. Such lower energy use may include no forced air, no requirement to drop the temperature of the second air chamber or ice forming plate, and harvesting can be done with minimal heating to the ice forming plate over a longer period of time, if needed.
Additionally, in certain embodiments the controller 440 is able to individually control the different systems, allowing at least one system 452 to be directed to operate in a low energy mode while at least one other system 452 is directed to operate in a high energy mode.
It will be understood by one having ordinary skill in the art that construction of the described invention and other components is not limited to any specific material. Other exemplary embodiments of the invention disclosed herein may be formed from a wide variety of materials, unless described otherwise herein. In this specification and the amended claims, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise.
Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range, and any other stated or intervening value in that stated range, is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges, and are also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention.
It is also important to note that the construction and arrangement of the elements of the invention as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.
It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present invention. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.
It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.
Claims
1. An adaptive ice maker for making clear ice pieces, comprising:
- a sensor which detects a usage parameter of the ice maker and transmits the usage parameter to a controller;
- wherein the controller is operably connected to a plurality of ice forming systems; and
- wherein the controller directs the ice forming systems to operate in a high energy mode or in a low energy mode based on the usage parameter.
2. The adaptive ice maker of claim 1, wherein the ice maker dispenses the clear ice pieces into an ice bin such that the clear ice pieces reach a level L in the ice bin, and wherein the usage parameter is the level L of clear ice pieces in the ice bin.
3. The adaptive ice maker of claim 1, wherein the ice maker dispenses the clear ice pieces into an ice bin such that the clear ice pieces reach a level L1 in the ice bin at a first time, and the clear ice pieces reach a level L2 in the ice bin at a second time, and wherein the usage parameter is the change in the level (L1-L2) of clear ice pieces in the ice bin from the first time to the second time.
4. The adaptive ice maker of claim 1, wherein the ice maker has a dispenser which is actuated by a user for a length of time t to dispense clear ice pieces, and wherein the usage parameter is the length of time t that the dispenser has been actuated.
5. The adaptive ice maker of claim 1, wherein the ice forming systems include a thermoelectric cooling device coupled with a bottom surface of an ice forming plate, and wherein the thermoelectric cooling device is operable at a wattage W1, and at a wattage W2, where W1 is greater than W2, and wherein the thermoelectric cooling device is operated at the wattage W1 when the controller directs operation in the high energy mode.
6. The adaptive ice maker of claim 5, wherein the ice maker further comprises:
- an ice tray horizontally suspended within a housing, having a top surface and a bottom surface;
- a barrier extending from the housing and surrounding a periphery of the ice tray to define a first air chamber above the ice tray and a second air chamber below the ice tray;
- a heat sink thermally coupled with the thermoelectric cooling device and extending within the second air chamber;
- a cold air intake duct member coupled with the housing proximate the second air chamber, wherein the cold air intake duct member is configured to dispense a cold air flow over the heat sink;
- a cold air exhaust duct member coupled with the housing proximate the second air chamber for receiving the cold air flow after it flows over the heat sink; and
- wherein the ice forming systems include a forced air system, wherein the forced air system comprises a cold air circulating device which circulates the cold air flow over the heat sink; and
- wherein the cold air circulating device is operable at a flow rate F1 and a flow rate F2, wherein F1 is greater than F2, and wherein the cold air circulating device is operated at the flow rate F1 when the controller directs operation in the high energy mode.
7. The adaptive ice maker of claim 5, wherein the ice maker further comprises:
- an ice tray horizontally suspended within a housing, having a top surface and a bottom surface;
- a barrier extending from the housing and surrounding a periphery of the ice tray to define a first air chamber above the ice tray and a second air chamber below the ice tray;
- a warm air intake duct member coupled with the housing proximate the first air chamber, wherein the warm air intake duct member is configured to dispense a warm air flow through the first air chamber;
- a warm air exhaust duct member coupled with the housing proximate the first air chamber for receiving the warm air flow; and
- wherein the ice forming systems include a forced air system, wherein the forced air system comprises a warm air circulating device which circulates the warm air flow through the first air chamber; and
- wherein the warm air circulating device is operable at a flow rate F3 and a flow rate F4, wherein F3 is greater than F4, and wherein the warm air circulating device is operated at the flow rate F3 when the controller directs operation in the high energy mode.
8. The adaptive ice maker of claim 7, wherein the ice maker further comprises:
- a heat sink thermally coupled with the thermoelectric cooling device and extending within the second air chamber;
- a cold air intake duct member coupled with the housing proximate the second air chamber, wherein the cold air intake duct member is configured to dispense a cold air flow over the heat sink;
- a cold air exhaust duct member coupled with the housing proximate the second air chamber for receiving the cold air flow after it flows over the heat sink;
- wherein the ice forming systems include a forced cold air system, wherein the forced cold air system comprises a cold air circulating device which circulates the cold air flow over the heat sink; and
- wherein the cold air circulating device is operable at a flow rate F1 and a flow rate F2, wherein F1 is greater than F2, and wherein the cold air circulating device is operated at the flow rate F1 when the controller directs operation in the high energy mode.
9. The adaptive ice maker of claim 1, wherein the controller directs each of the plurality of ice forming systems to operate in a high energy mode or in a low energy mode independently, such that at least one system is directed to operate in the low energy mode while at least one system is directed to operate in the high energy mode.
10. An adaptive ice maker for making clear ice pieces, comprising:
- a sensor which detects a usage parameter of the ice maker and transmits the usage parameter to a controller;
- wherein the controller is operably connected to a plurality of ice forming systems; and
- wherein the controller directs the ice forming systems to operate in a first energy mode, a second energy mode, or a third energy mode, wherein the first energy mode requires more energy than the second energy mode, and the second energy mode requires more energy than the third energy mode.
11. The adaptive ice maker of claim 10,
- wherein the ice maker has a dispenser which is actuated by a user for a length of time t to dispense clear ice pieces;
- wherein the ice maker deposits the clear ice pieces into an ice bin such that the clear ice pieces reach a level L1 in the ice bin at a first time, and the clear ice pieces reach a level L2 in the ice bin at a second time; and
- wherein the usage parameter is chosen from the group comprising the level L1 of clear ice pieces in the ice bin, the change in the level (L1-L2) of clear ice pieces in the ice bin, the length of time t that the dispenser has been actuated, or a combination thereof.
12. The adaptive ice maker of claim 10, wherein the ice forming systems include a thermoelectric cooling system having a thermoelectric device thermally coupled to a bottom surface of an ice forming plate to cool the ice forming plate, a forced air system which circulates cold air over a heat sink coupled to the thermoelectric cooling device, a forced air system which circulates warm air over the top surface of the ice forming plate, a housing having a first air chamber and a second air chamber with a temperature control system which maintains a temperature gradient between the first air chamber and the second air chamber.
13. The adaptive ice maker of claim 12, further comprising a harvest aid, wherein the harvest aid is the thermoelectric device thermally coupled to the bottom surface of the ice forming plate, and the thermoelectric device is operable to heat the ice forming plate.
14. A method of forming ice, comprising the steps of:
- measuring ice usage parameters;
- determining whether to operate a plurality of ice forming systems of an ice maker in a high energy mode or a low energy mode based on the usage parameters.
15. The method of claim 14,
- wherein the ice maker has a dispenser which is actuated by a user for a length of time t to dispense clear ice pieces;
- wherein the ice maker deposits the clear ice pieces into an ice bin such that the clear ice pieces reach a level L1 in the ice bin at a first time, and the clear ice pieces reach a level L2 in the ice bin at a second time; and
- wherein the usage parameter is chosen from the group comprising the level L1 of clear ice pieces in the ice bin, the change in the level (L1-L2) of clear ice pieces in the ice bin, the length of time t that the dispenser has been actuated, or a combination thereof.
16. The method of claim 14, wherein the plurality of ice forming systems of the ice maker are chosen from the group consisting of a thermoelectric cooling system having a thermoelectric device thermally coupled to a bottom surface of an ice forming plate to cool the ice forming plate, a forced air system which circulates cold air over a heat sink coupled to the thermoelectric cooling device, a forced air system which circulates warm air over the top surface of the ice forming plate, a housing having a first air chamber and a second air chamber with a temperature control system which maintains a temperature gradient between the first air chamber and the second air chamber.
17. The method of claim 14, wherein the usage parameter is chosen from the group comprising a measurement of the time of day or a historical ice usage pattern.
18. The method of claim 14, wherein using the ice maker in the high energy mode results in the production of ice more quickly than using the ice maker in the low energy mode.
19. The method of claim 18, wherein using the ice maker in the low energy mode requires less energy to produce a given volume of ice than using the ice maker in the high energy mode.
Type: Application
Filed: Dec 13, 2012
Publication Date: Jun 19, 2014
Applicant: WHIRLPOOL CORPORATION (Benton Harbor, MI)
Inventor: PATRICK J. BOARMAN (Evansville, IN)
Application Number: 13/713,253
International Classification: F25C 5/18 (20060101); F25C 5/08 (20060101);