REFRIGERATOR AND METHOD OF MANUFACTURING ICE MAKER THEREFOR

According to an embodiment, an ice maker comprises: a main body having a cooling space supplied with the cold air generated by a cooling module; an ice making assembly comprising an ice tray arranged in the cooling space to generate ice and a rotation module configured for rotating at least one of the ice tray and rotating an ejector for ejecting the ice from the ice tray; an ice bucket disposed at a lower side of the ice making assembly configured to receive the ice from the ice tray; a transfer assembly configured for transferring the ice collected in the ice bucket to an ice discharge module; and a full ice detection module configured for detecting whether the ice bucket is full of the ice. The full ice detection module comprises: a first sensor mounted to the rotation module configured to emit light; a reflective element coupled to the transfer assembly and configured to reflect the light emitted from the first sensor; and a second sensor coupled to the rotation module and spaced apart from the first sensor by a predetermined distance to allow detection of the light reflected by the reflective element.

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Description
RELATED APPLICATION

This application claims priority to Korean Patent Application No. 10-2015-0086163, filed Jun. 17, 2015, hereby incorporated by reference in its entirety.

FIELD

Embodiments of the present invention generally relate to a refrigerator and a method of manufacturing an ice maker therefor.

BACKGROUND

A refrigerator is an appliance for storing foods at low temperature, and may store foods in a frozen or refrigerated state according to the type of food.

The interior of the refrigerator is cooled by continuously supplied cold air, and the cold air is generated through heat exchange with refrigerant by a refrigeration cycle performing a compression-condensation-expansion-evaporation process. The cold air supplied into the refrigerator is evenly transferred to the interior of the refrigerator by convection and thus the foods in the refrigerator may be maintained at a desired temperature.

The refrigerator typically has a rectangular main body which is open at a front surface thereof. The main body may have a refrigerating chamber and a freezing chamber therein. The front surface of the main body may be disposed with a refrigerating chamber door and a freezing chamber door, for selectively opening a portion of the refrigerator. The refrigerator may include a plurality of drawers, shelves, and storage boxes, etc., in order to optimally store various foods in an internal storage space of the refrigerator.

Conventionally, a top-mount type refrigerator, in which a freezing chamber is located in the upper portion and a refrigerating chamber is located in the lower portion, has been used. In recent years, a bottom-freezer type refrigerator, in which a freezing chamber is located in the lower portion, has been also developed in order to increase user convenience. The bottom-freezer type refrigerator has an advantage in that it is convenient for a user to frequently utilize a refrigerating chamber since it is located in the upper portion and the relatively less used freezing chamber is located in the lower portion. However, the bottom-freezer type refrigerator is inconvenient for user access to ice in the freezing chamber because the user has to bend over to access the freezing chamber.

In order to resolve this problem, another bottom-freezer type refrigerator in which a dispenser for getting ice is disposed in the refrigerating chamber door located at the upper portion of the refrigerator has been recently developed. In this case, an ice maker for generating ice may be disposed in the refrigerating chamber door or within the refrigerating chamber.

The ice maker may include an ice making assembly which generates ice and includes an ice tray, an ice bucket which stores the generated ice, and a transfer assembly which transfers the ice stored in the ice bucket to a dispenser.

Specifically, the ice made by the ice making assembly may be dropped into and be collected in the ice bucket located beneath the ice tray. The conventional ice maker includes a detection lever, a sensor, or the like capable of detecting whether or not the amount of ice collected in the ice bucket exceeds a predetermined amount. The ice maker may be controlled such that the operation of the ice maker is stopped when the amount of ice exceeds the predetermined amount.

However, since the conventional detection lever or sensor has a very limited ability to detect ice, there is a problem in that the amount of ice collected in the ice bucket is not accurately detected.

In addition, since the sensor is mounted to the ice maker equipped with a plurality of components in a small space, in that the ice maker is complicated to manufacture.

SUMMARY

Therefore, the present invention has been made in view of the above problems, and it is an object of the present invention to provide a refrigerator including an ice maker capable of accurately detecting whether or not an ice bucket is full of ice.

It is another object of the present invention to provide a method of manufacturing an ice maker for a refrigerator, in which a full ice detection module is easily mounted to an ice maker.

According to an embodiment, a refrigerator comprising: a case having a food storage space; a cooling module configured for generating cold air and comprising a compressor, a condenser, an expansion valve, and an evaporator; a door disposed on the case to shield the food storage space; and an ice maker disposed in at least one of the food storage space and the door, wherein the ice maker comprises: a main body having a cooling space supplied with the cold air generated by the cooling module; an ice making assembly comprising an ice tray arranged in the cooling space to generate ice and a rotation module configured for rotating at least one of the ice tray and an ejector for ejecting the ice from the ice tray; an ice bucket disposed at a lower portion of the ice making assembly configured to receive the ice (e.g., dropped) from the ice tray; a transfer assembly configured for transferring the ice collected in the ice bucket to an ice discharge module; and a full ice detection module configured for detecting whether or not the ice bucket is full of the ice, and wherein the full ice detection module comprises: a first sensor mounted to the rotation module configured to emit light; a reflective element coupled to the transfer assembly and configured to reflect the light emitted from the first sensor; and a second sensor mounted to the rotation module and spaced apart from the first sensor by a predetermined distance to allow detection of the light reflected by the reflective element.

Further, wherein the light emitted from the first sensor is refracted through the reflective element and is then received by the second sensor.

Further, wherein the ice making assembly further comprises a cold air guide module provided at a lower side of the ice tray so as to guide the cold air supplied from the cooling module to the lower side of the ice tray.

Further, wherein the first sensor is inserted into a first mounting portion disposed in a lower portion of the rotation module, and the second sensor is inserted into a second mounting portion disposed in the lower portion of the rotation module, the second mounting portion being spaced apart from the first mounting portion by a predetermined distance.

Further, wherein the transfer assembly comprises: an auger for transferring the ice; an auger motor for driving the auger; and an auger motor housing for accommodating the auger motor, and wherein the reflective element is coupled to the auger motor housing.

Further, wherein the first sensor and the reflective element are mounted at diagonal points on a rectangular portion of a plane formed by a back surface of the ice tray extending toward the transfer assembly.

Further, wherein the second sensor and the reflective element are mounted at diagonal points on the rectangular portion of the plane formed by the back surface of the ice tray extending toward the transfer assembly.

Further, wherein the light emitted from the first sensor moves along a zigzag path between the first sensor, the reflective element, and the second sensor.

Further, wherein the reflective element is detachably mounted to the transfer assembly by a third mounting portion disposed in the transfer assembly.

Further, wherein the third mounting portion has a slot into which the reflective element is slidably inserted.

According to an embodiment, a method of manufacturing an ice maker for a refrigerator, comprising: manufacturing an ice maker comprising an ice making assembly, an ice bucket, and a transfer assembly; mounting a first and a second sensor of a full ice detection module to a rotation module of the ice making assembly, wherein the full ice detection module is configured for detecting whether the ice bucket is full of ice, and mounting a reflective element of the full ice detection module to an auger motor housing of the transfer assembly; adjusting positions of the first and second sensors mounted to the rotation module and a position of the reflective element mounted to the auger motor housing such that the first sensor, the reflective element, and the second sensor are optically (e.g., operatively) coupled to each other; and assembling the transfer assembly to one side of the ice bucket and assembling the ice making assembly to an upper side of the ice bucket.

Further, the ice making assembly comprises an ice tray arranged above the ice bucket; and the first sensor, the reflective element, and the second sensor are mounted in a zigzag arrangement at diagonal points of a rectangular portion of a plane formed by a back surface of the ice tray extending toward the transfer assembly.

Further, wherein the reflective element is detachably coupled to the auger motor housing.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a view illustrating an exemplary ice maker disposed in a refrigerator according to an embodiment of the present invention;

FIG. 2 is a side cross-sectional view illustrating the ice maker in FIG. 1;

FIG. 3 is an exploded perspective view illustrating the ice maker in FIG. 2;

FIG. 4 is a view illustrating a reflective element is provided in an auger motor housing of the ice maker in FIG. 2;

FIG. 5 is a view for explaining the operation and function of a full ice detection module of the ice maker in FIG. 4; and

FIG. 6 is a flowchart illustrating a method of manufacturing the ice maker according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Exemplary embodiments of the present invention will be described below in detail with reference to the accompanying drawings. In certain embodiments, detailed descriptions of relevant constructions or functions well known in the art may be omitted to avoid obscuring appreciation of the disclosure.

FIG. 1 is a view illustrating an exemplary ice maker disposed in a refrigerator according to an embodiment of the present invention. FIG. 2 is a side cross-sectional view illustrating an ice maker in FIG. 1. FIG. 3 is an exploded perspective view illustrating the ice maker in FIG. 2.

Referring to FIGS. 1 to 3, an ice maker 10 for a refrigerator capable of detecting whether or not an ice bucket 320 is full of ice is shown. The ice maker 10 may include a main body 100, a cooling module (not shown), an ice making assembly 200, an ice bucket 320, a transfer assembly 400, and a full ice detection module.

The refrigerator 1 according to the embodiment may include a case 2 defining an external structure and/or appearance thereof, a barrier 4 which divides a food storage space partitioning the case 2 into an upper refrigerating chamber R and a lower freezing chamber F, refrigerating chamber doors 3 disposed at both front edges of the case 2 to selectively open and close the refrigerating chamber R by rotation thereof, and a freezing chamber door 5 which functions as a front opening portion of the freezing chamber F. Although the ice maker is illustrated as being disposed at one side of an upper portion of the refrigerating chamber R in the embodiment, this is by way of example only. Alternatively, the ice maker 10 may be installed at a different position in the refrigerating chamber R or in a different place such as the refrigerating chamber door 3.

The main body 100 of the ice maker 10 may have a cooling space 105 in which ice may be generated. The ice making assembly 200 may be disposed at an upper side in the cooling space 105 and the ice bucket 320 may be arranged at a lower side of the ice making assembly 200. The cooling module functions to generate cold air and supply the generated cold air to an ice tray 210. The cooling module may include a compressor, a condenser, an expansion valve, an evaporator, etc. which performs a cooling cycle. The cooling module generates cold air by exchanging heat between a refrigerant and air. Cold air may be supplied to the ice tray 210 through a discharge duct 310 and a cold air guide module 220 by a blower or the like.

The ice making assembly 200 includes an ice tray 210 which receives water, a cold air guide module 220 which guides the flow of cold air such that the cold air supplied from the cooling module moves along a back surface of the ice tray 210, and a rotation module 230 which rotates the ice tray 210 to drop the ice into the ice bucket 320.

The ice tray 210 provides a space in which water supplied from a water supply pipe (not shown) or the like is cooled to produce ice, and has a plurality of ice forming spaces formed on an upper surface thereof to accommodate water. The forming spaces may have various shapes according to the shape of ice to be made, and the number of forming spaces may be vary.

The ice tray 210 may be made of metal having high thermal conductivity, e.g., aluminum. The ice tray 210 may improve a heat exchange rate between water and cold air due to having a high thermal conductivity. Consequently, the ice tray 210 may serve as a type of heat exchanger. Although not illustrated, the back surface of the ice tray 210 may be provided with cooling ribs or the like for increasing surface area contact with the cold air.

Meanwhile, the cold air guide module 220 functions to guide the cold air supplied from the cooling module to the lower side of the ice tray 210. The cold air guide module 220 may be coupled to the discharge duct 310 as a passage through which the cold air is supplied from the cooling module. The cold air guide module 220 may include cold air guide elements 221 and 222 coupled to at least one surface of the discharge duct 310, and may include a first cold air guide element 221 extending from an upper surface of the discharge duct 310 and a second cold air guide element 222 extending from a lower surface of the discharge duct 310.

The first cold air guide element 221 may be coupled between the upper surface of the discharge duct 310 and a bracket 221 to which the ice tray 210 is mounted. The second cold air guide element 222 may extend from the lower surface of the discharge duct 310 and be spaced apart from the back surface of the ice tray 210. Thus, a cold air passage 225 for cold air flow may be formed between the back surface of the ice tray 210 and an upper surface of the second cold air guide element 222.

The cold air guided by the cold air guide elements 221 and 222 may flow toward the back surface of the ice tray 210, and may exchange heat with the ice tray 210 so that the water present in the ice tray 210 is transformed into ice.

The ice made in the above manner may be dropped into the ice bucket 320 disposed beneath the ice tray 210 by the rotation module 230. Specifically, the upper surface of the ice tray 210 may be turned toward the ice bucket 320 by rotation of a rotary shaft 234, and the ice tray 210 may be twisted (e.g., distorted) by contact with a fixed element (not shown) when rotating beyond a specific angle. Consequently, through the twisting of the ice tray 210, ice in the ice tray 210 may be dropped into the ice bucket 320.

In addition, a plurality of ejectors (not shown) may be disposed in the rotary shaft 234 so ice is ejected from the ice tray 210 by rotation of the ejectors, without the rotation of the ice tray 210.

The rotary shaft 234 may be driven by an ice maker driving module 232, and the ice maker driving module 232 may be coupled in the ice making space 105 by an ice maker fixture 233.

Moreover, the ice tray 210 may be equipped with a deicing heater 231 which heats a surface of the ice tray 210 during or before rotation of the rotary shaft 234. Ice may be separated from the ice tray 210 in a manner that melts the surface of the ice in the ice tray 210 with heat from the deicing heater 231.

The transfer assembly 400 transfers ice toward an ice discharge module 600, and may include an auger 410 and an auger motor 420. The auger 410 may be a rotatable element having blades in a screw or spiral form, and is rotated by the auger motor 420. The auger 410 may be disposed in the ice bucket 320. Ice collected in the ice bucket 320 may be inserted between the blades of the auger 410 to be transferred toward the ice discharge module 600 by rotation of the auger 410. The auger motor 420 may be disposed in an auger motor housing 430.

The ice discharge module 600 may be connected to a dispenser (not shown) disposed in one of the refrigerating chamber doors 3, and the ice transferred by the transfer assembly 400 may be supplied to a user through the dispenser according to an activation thereof by the user. Although not illustrated, the ice discharge module 600 may have a cutting element for cutting ice into a predetermined size.

FIG. 4 is a view illustrating a reflective element disposed on the auger motor housing of the ice maker in FIG. 2. FIG. 5 is a view for explaining the operation and effect of the full ice detection module of the ice maker in FIG. 4.

Referring to FIGS. 4 and 5, the full ice detection module detects that ice is collected in the ice bucket 320 beyond a certain extent, that is, detects whether the ice bucket 320 is full of ice. The full ice detection module may include a pair of first and second sensors 510 and 520 and a reflective element 530, which are mounted to the rotation module 230 and the auger motor housing 430, respectively. The sensors 510 and 520 may be photo sensors such as infrared sensors, and may be configured as a light-emitting sensor and a light-receiving sensor for instance.

The light-emitting sensor is a sensor configured for emitting light which may be blocked by ice, and the light-receiving sensor is a sensor configured for detecting light. When light emitted from the light-emitting sensor is not received by the light-receiving sensor, it may be determined that a blocking material, namely ice, is present in a path of light. In an exemplary embodiment, the first sensor 510 is a light-emitting sensor and the second sensor 520 is a light-receiving sensor where are described below.

The heights (e.g., y-axis coordinates) at which the first and second sensors 510 and 520 and the reflective element 530 of the full ice detection module are mounted to the rotation module 230 and the auger motor housing 430 vary according to the limited amount of ice which may be accommodated in the ice bucket 320 (hereinafter, referred to as the “predetermined limited capacity”). The first and second sensors 510 and 520 and the reflective element 530 of the full ice detection module may be coupled to the rotation module 230 and the auger motor housing 430 at the relevant heights.

The reflective element 530 may be include a reflective material for reflecting light emitted from the first sensor 510, and may be an element having a flat reflective surface in order to provide uniform reflection. The light emitted from the first sensor 510 may be received by the second sensor 520 via the reflective element 530.

The reflective elements 530 may be designed as illustrated in FIG. 4, and there may also be multiple reflective elements. In addition, the reflective element 530 may also be coupled to an entire surface of the auger motor housing 430.

The light emitted from the first sensor 510 may sequentially pass through the reflective element 530 and the second sensor 520 along a zigzag path (e.g., as shown by the dotted line in FIG. 5).

The first and second sensors 510 and 520 may be mounted to a lower portion of the ice maker fixture 233 of the rotation module 230 in in which the first and second sensors 510 and 520 are spaced apart from each other. The reflective element 530 may be mounted to the auger motor housing 430. In this case, the first and second sensors 510 and 520 may be mounted to the rotation module 230 through a first mounting portion 511 and a second mounting portion (not shown) having respective grooves into which the first and second sensors 510 and 520 are inserted therein.

The reflective element 530 may be coupled to the auger motor housing 430, or may be detachably mounted through a third mounting portion 531 disposed in the auger motor housing 430. The third mounting portion 531 may have a slot into which the reflective element 530 is slidably inserted, and the reflective element 530 may be fixed to the third mounting portion 531 by a supporting, gripping, or friction fit piece 532.

The first sensor 510 and the reflective element 530 may be mounted at diagonal points on a rectangular portion of a plane (e.g., x-z plane) formed by the back surface of the ice tray 210 extending toward the transfer assembly 400. In addition, the reflective element 530 and the second sensor 520 may be mounted at diagonal points the rectangular portion of in the plane (e.g., x-z plane) formed by the back surface of the ice tray 210 extending toward the transfer assembly 400. That is, the first and second sensors 510 and 520 and the reflective element 530 may be mounted at different points on the z-axis.

Hereinafter, the operation and results or functions of the ice maker according to the embodiment of the present invention will be described.

In the ice maker 10 according to an embodiment, cold air generated through the compressor, the condenser, the expansion valve, and the evaporator may be supplied to the cooling space 105 via the discharge duct 310. The cold air may freeze water placed in the ice tray 210 disposed in the cooling space 105. In this case, since the cold air guide module 220 is connected to the discharge duct 310 and extending therefrom, the cold air discharged from the discharge duct 310 may move along the cold air guide module 220.

Referring to FIG. 2, the cold air may enter between the first guide element 221 and the second guide element 222 and may then move along the cold air passage 225 formed between the back surface of the ice tray 210 and the second guide element 222. The cold air exchanges heat with the back surface of the ice tray 210 while moving along the back surface of the ice tray 210, and may cool water in the ice tray 210 so as to form ice. The ice made in the ice tray 210 may be dropped downward by rotation of the rotary shaft 234 and may be collected in the ice bucket 320 arranged beneath the ice tray 210.

As ice is generated, the amount of ice collected in the ice bucket 320 may exceed a predetermined limited capacity of the ice bucket 320. In this case, the full ice detection module may detect whether or not the amount of ice collected in the ice bucket 320 exceeds the predetermined limited capacity of the ice bucket 320.

Referring to FIG. 5, the first sensor 510 may constantly or periodically emit light, and the light emitted from the first sensor 510 reaches the reflective element 530 located on the diagonal path. The light reaching the reflective element 530 is reflected (e.g., and refracted) by the reflective element 530 and is received by the second sensor 520 located on the diagonal path in the opposite direction.

When the light passing through the diagonal path is received by the second sensor 520, the amount of ice collected in the ice bucket 320 may be determined to be less than the predetermined limited capacity of the ice bucket 320.

When ice is accumulates in the ice bucket 320 and exceeds a predetermined height, e.g., to the detection height of the full ice detection module, light emitted from the first sensor 510 hits the ice and the light is not received by the second sensor 520. Accordingly, a control unit (not shown) may determine whether the ice bucket 320 is full of ice. Then, the control unit may stop the driving of the rotation module 230 and may stop and/or pause the operation of the components for manufacturing ice.

The reflective element 530 is disposed between the first and second sensors 510 and 520, thereby enabling the path of light emitted from the first sensor 510 to reach the second sensor. Consequently, the region in which the full ice detection module can detect whether the ice bucket is full of ice may be enlarged.

In addition, the range of the detection region may be adjusted by adding additional reflective elements. Since the detection region can be enlarged using one or more low-priced reflective elements instead of a relatively expensive sensor, thereby reducing manufacturing cost.

Moreover, when the reflective element 530 is located on the auger motor housing 430, it may be possible to detect whether or not ice is fully present in other portions of the auger 410 and the like as well as in a lower region of the ice tray 210.

The full ice detection modules replaces a mechanical full ice detection structure and thereby the number of parts and assembly processes may be reduced and thus manufacturing costs may be reduced.

Furthermore, since the detection region for detecting whether the ice bucket is full of ice is enlarged, factors contributing to malfunctions due to full ice detection errors may be removed, and thus the ice maker may have improved reliability.

Hereinafter, a method of manufacturing the ice maker according to an embodiment of the present invention will be described.

FIG. 6 is a flowchart illustrating an exemplary method of manufacturing the ice maker according to an embodiment of the present invention.

Referring to FIGS. 1 to 6, the above-mentioned ice maker 10 the ice making assembly 200, the ice bucket 320, and the transfer assembly 400. In order to manufacture the ice maker 10 according to an embodiment, the ice making assembly 200, the ice bucket 320, and the transfer assembly 400, which constitute the ice maker 10, are individually manufactured in the known manner (S100). The first and second sensors 510 and 520 of the full ice detection module for detecting whether the ice bucket 320 is full of ice are mounted to the rotation module 230 of the ice making assembly 200 and the reflective element 530 is mounted to the auger motor housing 430 of the transfer assembly 400 (S200).

In this case, the first sensor 510 may be inserted into a groove of the first mounting portion 511, and the second sensor 520 may be inserted into the groove of the second mounting portion. The reflective element 530 may be slidably inserted into the slot of the third mounting portion 531.

The first sensor 510, the reflective element 530, and the second sensor 520 may be mounted in a zigzag arrangement at the diagonal points on a rectangular portion of a plane formed by the back surface of the ice tray 210 extending toward the transfer assembly 400. The positions of the first and second sensors 510 and 520 mounted to the rotation module 230 and the position of the reflective element 530 mounted to the auger motor housing 430 may be adjusted such that the first sensor 510, the reflective element 530, and the second sensor 520 are optically and/or operatively coupled to each other (S300). That is, the positions of the first sensor 510, the reflective element 530, and the second sensor 520 may be adjusted such that light emitted from the first sensor 510 is reflected (e.g., and refracted) by the reflective element 530 and is then received by the second sensor 520.

The position adjustment for optically and/or operatively interconnecting the first sensor 510, the reflective element 530, and the second sensor 520 may be simplified as the reflective element 530 covers an entire surface of the auger motor housing 430 or the reflective element 530 has an increased reflective area.

When the position adjustment of the first sensor 510, the reflective element 530, and the second sensor 520 is completed, the transfer assembly 400 may be assembled to one side of the ice bucket 320 and the ice making assembly 200 may be assembled to the upper side of the ice bucket 320 (S400). The ice maker 10 manufacture may be completed by additionally assembling the main body 100, the ice discharge module 600, etc., to form the ice maker 10.

Since the first sensor 510, the reflective element 530, and the second sensor 520 of the full ice detection module are mounted to different assemblies, the region detected by the full ice detection module may be enlarged to support different assemblies. In addition, the positions at which the first sensor 510, the reflective element 530, and the second sensor 520 are optically and/or operatively coupled to each other may be configured such that the reflective element 530 is separated from the third mounting portion 531. After the positions of the first sensor 510, the reflective element 530, and the second sensor 520 are set, the reflective element 530 may be inserted into the third mounting portion 531.

That is, since the reflective element 530 is detachably mounted to the auger motor housing 430, the operation for optical and/or operatively coupled the first sensor 510, the reflective element 530, and the second sensor 520 may be easily performed even though the reflective element 530 is coupled to a separate assembly from the first and second sensors 510 and 520.

In accordance with exemplary embodiments of the present invention, it may be possible to provide a refrigerator including an ice maker capable of accurately detecting whether or not an ice bucket is full of ice.

In addition, it may be possible to provide a method of manufacturing the ice maker for the refrigerator, in which a full ice detection module is easily mounted to the ice maker.

Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims. More particularly, various variations and modifications are possible in constituent elements of the embodiments. In addition, it is to be understood that differences relevant to the variations and modifications fall within the spirit and scope of the present disclosure defined in the appended claims.

Claims

1. A refrigerator comprising:

a case comprising a food storage space;
a cooling module comprising a compressor, a condenser, an expansion valve, and an evaporator and configured to generate cold air;
a door disposed on the case to shield the food storage space; and
an ice maker installed in at least one of the food storage space and the door,
wherein the ice maker comprises:
a main body having a cooling space for receiving the cold air generated by the cooling module;
an ice making assembly comprising: an ice tray disposed in the cooling space to generate ice; and a rotation module configured for rotating at least one of the ice tray and an ejector for ejecting the ice from the ice tray;
an ice bucket disposed at a lower side of the ice making assembly to receive the ice from the ice tray;
a transfer assembly configured for transferring the ice collected in the ice bucket to an ice discharge module; and
a full ice detection module configured for detecting whether the ice bucket is full of the ice, and
wherein the full ice detection module comprises:
a first sensor coupled to the rotation module and configured to emit light;
a reflective element coupled to the transfer assembly and configured to reflect the light emitted from the first sensor; and
a second sensor coupled to the rotation module, wherein the second sensor is spaced apart from the first sensor by a predetermined distance to allow detection of the light reflected by the reflective element.

2. The refrigerator according to claim 1, wherein the light emitted from the first sensor is refracted through the reflective element and is then received by the second sensor.

3. The refrigerator according to claim 1, wherein the ice making assembly further comprises a cold air guide module disposed at a lower side of the ice tray and configured to guide the cold air supplied from the cooling module to the lower side of the ice tray.

4. The refrigerator according to claim 1, wherein the first sensor is inserted into a first mounting portion disposed in a lower portion of the rotation module, and the second sensor is inserted into a second mounting portion disposed in the lower portion of the rotation module, wherein the second mounting portion being spaced apart from the first mounting portion by a predetermined distance.

5. The refrigerator according to claim 1, wherein the transfer assembly comprises:

an auger configured for transferring the ice;
an auger motor configured for driving the auger; and
an auger motor housing configured for coupling of the auger motor, and
wherein the reflective element is coupled to the auger motor housing.

6. The refrigerator according to claim 1, wherein the first sensor and the reflective element are coupled at diagonal points on a rectangular portion of a plane formed by a back surface of the ice tray extending toward the transfer assembly.

7. The refrigerator according to claim 6, wherein the second sensor and the reflective element are mounted at diagonal points on the rectangular portion of the plane formed by the back surface of the ice tray extending toward the transfer assembly.

8. The refrigerator according to claim 1, wherein the light emitted from the first sensor moves along a zigzag path between the first sensor, the reflective element, and the second sensor.

9. The refrigerator according to claim 1, wherein the reflective element is detachably coupled to the transfer assembly by a third mounting portion disposed in the transfer assembly.

10. The refrigerator according to claim 9, wherein the third mounting portion comprises a slot into which the reflective element can be slidably inserted.

11. A method of manufacturing an ice maker for a refrigerator, the method comprising:

manufacturing an ice making assembly, an ice bucket, and a transfer assembly forming an ice maker;
coupling a first and a second sensor of a full ice detection module to a rotation module of the ice making assembly;
coupling a reflective element of the full ice detection module to an auger motor housing of the transfer assembly, wherein the full ice detection module is configured for detecting whether the ice bucket is full of ice;
adjusting positions of the first and second sensors coupled to the rotation module and a position of the reflective element coupled to the auger motor housing to optically couple the first sensor, the reflective element, and the second sensor; and
assembling the transfer assembly to a side of the ice bucket and assembling the ice making assembly to an upper side of the ice bucket.

12. The method according to claim 11, wherein:

the ice making assembly comprises an ice tray disposed above the ice bucket; and
the first sensor, the reflective element, and the second sensor are coupled in a zigzag arrangement at diagonal points on a rectangular portion of a plane formed by a back surface of the ice tray extending toward the transfer assembly.

13. The method according to claim 11, wherein the reflective element is detachably coupled to the auger motor housing.

14. An apparatus for making ice, the apparatus comprising:

a main body having a cooling space configured for receiving cold air generated by a cooling module;
an ice making assembly comprising: an ice tray disposed in the cooling space to generate ice; and a rotation module configured for rotating at least one of the ice tray and an ejector for ejecting the ice from the ice tray;
an ice bucket disposed at a lower side of the ice making assembly to receive the ice from the ice tray;
a transfer assembly configured for transferring the ice collected in the ice bucket to an ice discharge module; and
a full ice detection module configured for detecting whether the ice bucket is full of the ice, wherein the full ice detection module comprises:
a first sensor coupled to the rotation module and configured to emit light;
a reflective element coupled to the transfer assembly and configured to reflect the light emitted from the first sensor; and
a second sensor coupled to the rotation module, wherein the second sensor disposed to allow detection of the light reflected by the reflective element.

15. The refrigerator according to claim 14, wherein the light emitted from the first sensor is refracted through the reflective element and is then received by the second sensor.

16. The apparatus according to claim 14, wherein the ice making assembly further comprises a cold air guide module disposed at a lower side of the ice tray and configured to guide the cold air supplied from the cooling module to the lower side of the ice tray.

17. The apparatus according to claim 14, wherein the first sensor is inserted into a first mounting portion disposed in a lower portion of the rotation module, and the second sensor is inserted into a second mounting portion disposed in the lower portion of the rotation module, the second mounting portion being spaced apart from the first mounting portion by a predetermined distance.

18. The apparatus according to claim 14, wherein the light emitted from the first sensor moves along a zigzag path between the first sensor, the reflective element, and the second sensor.

19. The apparatus according to claim 14, wherein the reflective element is detachably coupled to the transfer assembly by a third mounting portion disposed in the transfer assembly.

20. The apparatus according to claim 19, wherein the third mounting portion has a slot into which the reflective element can be slidably inserted.

Patent History
Publication number: 20160370080
Type: Application
Filed: Aug 25, 2015
Publication Date: Dec 22, 2016
Inventor: Sung Jin YANG (Seoul)
Application Number: 14/835,560
Classifications
International Classification: F25C 5/18 (20060101); F25C 1/24 (20060101); F25C 5/06 (20060101); F25D 23/00 (20060101); F25D 17/04 (20060101); F25D 29/00 (20060101); F25C 5/00 (20060101);