METHODS OF OPERATING AN ICE MAKER APPLIANCE

Abstract

A method of operating an ice maker appliance includes initially operating a motor of the ice maker appliance to rotate a mold body from an initial position, the initial position comprising one of a fill position or a complete harvest position of the mold body. Additionally, after initially operating the motor, the method includes detecting a rotational jam of the mold body. Furthermore, the method includes performing an operation associated with clearing the rotational jam of the mold body.

Description

FIELD

The present subject matter relates generally to ice maker appliances and to methods of operating such appliances.

BACKGROUND

Ice makers are commonly provided as stand-alone appliances or may be incorporated within larger refrigerated appliances used to store food items in both commercial and residential applications. Such appliances, e.g., stand-alone ice maker appliances and refrigerator appliances having an ice making assembly incorporated therein, may be collectively referred to as ice maker appliances. Typically, ice maker appliances include an ice making assembly configured for the bulk production of ice where, e.g., multiple pieces of ice are produced in a batch, and the batch of ice is then harvested from the ice making assembly. For example, the harvested ice may be collected and stored in a storage bin of the ice making appliance.

However, conventional ice maker appliances, particularly ice maker appliances with rotating trays, experience issues with tray positioning due to over rotating and/or under rotating the tray. As a result of improper tray positioning, ice pieces may not be harvested from the tray and/or rotational tray jams may occur, among other issues.

Accordingly, an ice maker with features for improved operation would be desirable. More particularly, ice maker appliances and related methods that include features to selectively position the rotating tray would be particularly beneficial.

BRIEF DESCRIPTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.

In one exemplary embodiment, a method of operating an ice maker appliance is provided. The ice maker appliance includes a mold body. Additionally, the ice maker appliance includes a motor coupled to the mold body. The motor is operable to rotate the mold body between a fill position and a complete harvest position. Furthermore, the ice maker appliance includes a controller. The controller is in operative communication with the motor. Moreover, the mold body receives a fill of liquid water in the fill position. Additionally, an ice piece is released from the mold body in the complete harvest position. The method includes initially operating, with the controller, the motor of the ice maker appliance to rotate the mold body from an initial position. The initial position includes one of the fill position or the complete harvest position. Furthermore, the method includes, after initially operating the motor, determining, with the controller, a rotational status of the mold body based on whether a signal indicating rotation of the mold body was emitted by a sensing device of the ice maker appliance. Moreover, the method includes selecting, with the controller, a length of time for which to operate the motor based on the determined rotational status of the mold body. Additionally, the method includes operating, with the controller, the motor for the selected length of time.

In another exemplary embodiment, a method of operating an ice maker appliance is provided. The ice maker appliance includes a mold body. Additionally, the ice maker appliance includes a motor coupled to the mold body. The motor is operable to rotate the mold body between a fill position and a complete harvest position. Furthermore, the ice maker appliance includes a controller. The controller is in operative communication with the motor. Moreover, the mold body receives a fill of liquid water in the fill position. Additionally, an ice piece is released from the mold body in the complete harvest position. The method includes initially operating, with the controller, the motor of the ice maker appliance to rotate the mold body from an initial position. The initial position includes one of the fill position or the complete harvest position. Additionally, the method includes after initially operating the motor, detecting, with the controller, a rotational jam of the mold body. Furthermore, the method includes performing, with the controller, a first operation associated with clearing the rotational jam of the mold body.

In another exemplary embodiment, an ice maker appliance is provided. The ice maker appliance includes a mold body. The mold body is configured to receive a fill of liquid water thereby permitting an ice piece to be formed. The mold body is rotatable between a fill position, in which the mold body receives the fill of liquid water, and a complete harvest position, in which the ice piece is released from the mold body. Furthermore, the ice maker appliance includes a motor. The motor is operatively coupled to the mold body. Additionally, the motor is operable to rotate the mold body between the fill position and the complete harvest position. Moreover, the ice maker appliance includes a sensing device. The sensing device is configured to emit a signal indicative of a rotation of the mold body. Furthermore, the ice maker appliance includes a controller. The controller is operatively coupled to the sensing device and the motor. The controller is configured to initially operate the motor to rotate the mold body. Additionally, after initially operating the motor, the controller is configured to determine a rotational status of the mold body based on whether the signal indicating the rotation of the mold body was emitted by the sensing device. Moreover, the controller is configured to select a length of time for which to continue operating the motor based on the determined rotational status of the mold body. Furthermore, the controller is configured to operate the motor for the selected length of time.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

FIG. 1 provides a perspective view of a refrigerator appliance according to an exemplary embodiment of the present subject matter.

FIG. 2 provides a perspective view of the exemplary refrigerator appliance of FIG. 1, with the doors of the fresh food chamber shown in an open position.

FIG. 3 provides an interior perspective view of a dispenser door of the exemplary refrigerator appliance of FIG. 1.

FIG. 4 provides an interior elevation view of the door of FIG. 3 with an access door of the door removes to reveal an ice making assembly therebehind.

FIG. 5 provides a sectional view the exemplary door and ice making assembly of FIGS. 3 and 4.

FIG. 6 provides a perspective view of the exemplary ice making assembly.

FIG. 7 provides a front view of the exemplary ice making assembly.

FIG. 8 provides a top view of the exemplary ice making assembly.

FIG. 9 provides a sectional view of the exemplary ice making assembly taken along a horizontal plane.

FIG. 10 provides a perspective view of the exemplary ice making assembly including a removable cartridge of the ice making assembly in a detached position.

FIG. 11 provides a perspective view of the exemplary ice making assembly without the removable cartridge.

FIG. 12 provides a perspective view of a carriage of the exemplary ice making assembly.

FIG. 13 provides a front view of the exemplary removable cartridge.

FIG. 14 provides a perspective view of the exemplary removable cartridge.

FIG. 15 provides a top view of the exemplary removable cartridge.

FIG. 16 provides a partial view of the exemplary removable cartridge.

FIG. 17 provides a perspective view of a mold body of the exemplary removable cartridge.

FIG. 18 provides a side view of the exemplary ice making assembly.

FIG. 19 provides a sectional view of the exemplary ice making assembly in a first position.

FIG. 20 provides a sectional view of the exemplary ice making assembly in a second position.

FIG. 21 provides a top view of the exemplary ice making assembly during a harvest operation.

FIG. 22 provides a perspective view of the exemplary ice making assembly during the harvest operation.

FIG. 23 provides another sectional view of the exemplary ice making assembly in the second position.

FIG. 24 provides a side view of the exemplary ice making assembly with a feeler arm of the ice making assembly in a second, e.g., up, position.

FIG. 25 provides a side view of the exemplary ice making assembly with the feeler arm of the ice making assembly in a first, e.g., down, position.

FIG. 26 provides a perspective view of a portion of the exemplary ice making assembly.

FIG. 27 provides a sectional view of a portion of the exemplary ice making assembly.

FIG. 28 provides a sectional view of another portion of the exemplary ice making assembly.

FIG. 29 provides a side view of the exemplary ice making assembly.

FIG. 30 provides a perspective view of the ice making assembly.

FIG. 31 provides a section view of a portion of the ice making assembly.

FIG. 32 provides a section view of a portion of the ice making assembly including a schematic illustration of a flow of air which may be directed to a portion of the ice making assembly in one or more exemplary embodiments of the present disclosure.

FIG. 33 provides a schematic illustration of an example sealed cooling system as may be used with a refrigerator appliance or other ice maker appliance in one or more exemplary embodiments of the present subject matter.

FIG. 34 provides a flow chart diagram of a first exemplary method of operating an ice maker appliance according to one or more embodiments of the present disclosure.

FIG. 35 provides a flow chart diagram of a second exemplary method of operating an ice maker appliance according to one or more embodiments of the present disclosure.

The use of the same reference numbers in the figures denotes the same or similar features unless the context indicates otherwise.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” In addition, references to “an embodiment” or “one embodiment” does not necessarily refer to the same embodiment, although it may. Any implementation described herein as “exemplary” or “an embodiment” is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). The term “at least one of” in the context of, e.g., “at least one of A, B, and C” refers to only A, only B, only C, or any combination of A, B, and C. In addition, here and throughout the specification and claims, range limitations may be combined and/or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.

Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,” “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and/or systems. For example, the approximating language may refer to being within a 10 percent margin, i.e., including values within ten percent greater or less than the stated value. In this regard, for example, when used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction, e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, e.g., clockwise or counterclockwise, with the vertical direction V.

Furthermore, the skilled artisan will recognize the interchangeability of various features from different embodiments. Similarly, the various method steps and features described, as well as other known equivalents for each such methods and features, can be mixed and matched by one of ordinary skill in this art to construct additional systems and techniques in accordance with principles of this disclosure. Of course, it is to be understood that not necessarily all such objects or advantages described above may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the systems and techniques described herein may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

FIG. 1 provides a perspective view of a refrigerator appliance 100 according to an exemplary embodiment of the present subject matter. Refrigerator appliance 100 includes a cabinet or housing 102 that extends between a top 104 and a bottom 106 along a vertical direction V, between a first side 108 and a second side 110 along a lateral direction L, and between a front side 112 and a rear side 114 along a transverse direction T. Each of the vertical direction V, lateral direction L, and transverse direction T are mutually perpendicular to one another.

Housing 102 defines chilled chambers for receipt of food items for storage. In particular, housing 102 defines fresh food chamber 122 positioned at or adjacent top 104 of housing 102 and a freezer chamber 124 arranged at or adjacent bottom 106 of housing 102. As such, refrigerator appliance 100 is generally referred to as a bottom mount refrigerator. In the exemplary embodiment, housing 102 also defines a mechanical compartment 62 (FIG. 1) for receipt of a sealed cooling system 60 (FIG. 33). It is recognized, however, that the benefits of the present disclosure apply to other types and styles of refrigerator appliances such as, e.g., a top mount refrigerator appliance, a side-by-side style refrigerator appliance, or a single door refrigerator appliance. Consequently, the description set forth herein is for illustrative purposes only and is not intended to be limiting in any aspect to any particular refrigerator chamber configuration.

Refrigerator doors 128 are rotatably hinged to an edge of housing 102 for selectively accessing fresh food chamber 122. In addition, a freezer door 130 is arranged below refrigerator doors 128 for selectively accessing freezer chamber 124. Freezer door 130 is coupled to a freezer drawer (not shown) slidably mounted within freezer chamber 124. Refrigerator doors 128 and freezer door 130 are shown in the closed configuration in FIG. 1. One skilled in the art will appreciate that other chamber and door configurations are possible and within the scope of the present invention.

FIG. 2 provides a perspective view of refrigerator appliance 100 shown with refrigerator doors 128 in the open position. As shown in FIG. 2, various storage components are mounted within fresh food chamber 122 to facilitate storage of food items therein as will be understood by those skilled in the art. In particular, the storage components may include bins 134 and shelves 136. Each of these storage components are configured for receipt of food items (e.g., beverages and/or solid food items, etc.) and may assist with organizing such food items. As illustrated, bins 134 may be mounted on refrigerator doors 128 or may slide into a receiving space in fresh food chamber 122. It should be appreciated that the illustrated storage components are used only for the purpose of explanation and that other storage components may be used and may have different sizes, shapes, and configurations.

Referring now generally to FIG. 1, a dispensing assembly 140 will be described according to exemplary embodiments of the present subject matter. Dispensing assembly 140 is generally configured for dispensing liquid water and/or ice. Although an exemplary dispensing assembly 140 is illustrated and described herein, it should be appreciated that variations and modifications may be made to dispensing assembly 140 while remaining within the present subject matter.

Dispensing assembly 140 and its various components may be positioned at least in part within a dispenser recess 142 defined on one of refrigerator doors 128. In this regard, dispenser recess 142 is defined on a front side 112 of refrigerator appliance 100 such that a user may operate dispensing assembly 140 without opening refrigerator door 128. In addition, dispenser recess 142 is positioned at a predetermined elevation convenient for a user to access ice and enabling the user to access ice without the need to bend over. In the exemplary embodiment, dispenser recess 142 is positioned at a level that approximates the chest level of a user.

Dispensing assembly 140 includes an ice dispenser 144 including a discharging outlet 146 for discharging ice from dispensing assembly 140. An actuating mechanism 148, shown as a paddle, is mounted below discharging outlet 146 for operating ice or water dispenser 144. In alternative exemplary embodiments, any suitable actuating mechanism may be used to operate ice dispenser 144. For example, ice dispenser 144 may include a sensing device (such as an ultrasonic sensing device) or a button rather than the paddle. Discharging outlet 146 and actuating mechanism 148 are an external part of ice dispenser 144 and are mounted in dispenser recess 142.

By contrast, inside refrigerator appliance 100, refrigerator door 128 may define an icebox 150 (FIGS. 2 through 4) housing an ice making assembly which includes an ice making assembly 200 and an ice storage bin (not shown, but which is understood to be positioned below the ice making assembly 200 for receiving ice pieces harvested from the ice maker, e.g., where the ice pieces fall by gravity from the ice making assembly 200 into the storage bin as a result of the harvest operation of the ice making assembly 200) that are configured to supply ice to dispenser recess 142. In this regard, for example, icebox 150 may define an ice making chamber 154 for housing an ice making assembly and a dispensing mechanism.

A control panel 160 is provided for controlling the mode of operation. For example, control panel 160 includes one or more selector inputs 162, such as knobs, buttons, touchscreen interfaces, etc., such as a water dispensing button and an ice-dispensing button, for selecting a desired mode of operation such as crushed or non-crushed ice. In addition, inputs 162 may be used to specify a fill volume or method of operating dispensing assembly 140. In this regard, inputs 162 may be in communication with a processing device or controller 164. Signals generated in controller 164 operate refrigerator appliance 100 and dispensing assembly 140 in response to selector inputs 162. Additionally, a display 166, such as an indicator light or a screen, may be provided on control panel 160. Display 166 may be in communication with controller 164 and may display information in response to signals from controller 164.

As used herein, “processing device” or “controller” may refer to one or more microprocessors or semiconductor devices and is not restricted necessarily to a single element. The processing device can be programmed to operate refrigerator appliance 100 and dispensing assembly 140. The processing device may include, or be associated with, one or more memory elements (e.g., non-transitory storage media). In some such embodiments, the memory elements include electrically erasable, programmable read only memory (EEPROM). Generally, the memory elements can store information accessible to the processing device, including instructions that can be executed by processing device. Optionally, the instructions can be software or any set of instructions and/or data that when executed by the processing device, cause the processing device to perform operations. For example, the instructions may include a software package configured to operate the system to, e.g., execute the exemplary methods described below. In exemplary embodiments, the various method steps as disclosed herein may be performed, e.g., in whole or part, by controller 164 and/or another, separate, dedicated controller.

Referring now to FIGS. 3 and 4, FIG. 3 provides an interior perspective view of one of the refrigerator doors 128 and FIG. 4 provides an interior elevation view of the door 128 with an access door 170 removed to more clearly depict the interior of the icebox 150. Refrigerator appliance 100 includes a sub-compartment 150 defined on refrigerator door 128. As mentioned above, the sub-compartment 150 may be referred to as an “icebox.” In the illustrated exemplary embodiment, icebox 150 extends into fresh food chamber 122 when refrigerator door 128 is in the closed position. In additional embodiments, the icebox 150 may be positioned on a freezer door, such as a single freezer door (e.g., in a side-by-side configuration or standalone freezer), a front of a slidable freezer drawer, or one of a pair of freezer doors (such as in a quad door refrigerator configuration). As shown in FIG. 4, the ice making assembly 200 may be positioned within the icebox 150.

As mentioned above, an access door 170 may be hinged to the inside of the refrigerator door 128. Access door 170 permits selective access to icebox 150. Any manner of suitable latch 172 may be configured with icebox 150 to maintain access door 170 in a closed position. As an example, latch 172 may be actuated by a consumer in order to open access door 170 for providing access into icebox 150. Access door 170 can also assist with insulating icebox 150, e.g., by thermally isolating or insulating icebox 150 from fresh food chamber 122.

The ice making assembly 200 is generally configured for freezing liquid water to form ice, e.g., ice pieces such as ice cubes or other shapes, which may optionally be stored in a storage bin or other storage mechanism and dispensed through discharging outlet 146 by dispensing assembly 140. For example, the ice making assembly 200 may include a mold body 210 having one or more mold cavities 226 (see, e.g., FIGS. 8-10 and 17) defined therein, such as in a removable cartridge 208 thereof (as will be described in further detail below), and liquid water may be directed into the mold cavity (or cavities) 226 of the ice making assembly 200, such as from a water supply line 202 and a nozzle 204. The ice making assembly 200 may include a fill cup 222 which may be generally aligned with the nozzle 204 to direct the liquid water to the mold body 210. Such water may then be retained in the mold body 210 at a temperature at or below the freezing point of water to form one or more ice pieces 1000. Chilled air from a sealed system (not shown) of refrigerator appliance 100 may be directed into or onto components, e.g., ice making assembly 200, within the icebox 150, in order to provide the temperature at or below the freezing point of water to form the ice piece or ice pieces 1000.

As mentioned above, the present disclosure may also be applied to other types and styles of refrigerator appliances such as, e.g., a top mount refrigerator appliance, a side-by-side style refrigerator appliance, or a standalone ice maker appliance. Variations and modifications may be made to ice making assembly while remaining within the scope of the present subject matter. Accordingly, the description herein of the icebox 150 on the door 128 of the fresh food chamber 122 is by way of example only. In other example embodiments, the ice making assembly may be positioned in the freezer chamber 124, e.g., of the illustrated bottom-mount refrigerator, of a side-by-side refrigerator, of a top-mount refrigerator, or any other suitable refrigerator appliance. As another example, the ice making assembly may also be provided in a standalone ice maker appliance. As used herein, the term “standalone ice maker appliance” refers to an appliance of which the sole or primary operation is generating or producing ice, e.g., without any additional or other chilled chambers other than the icebox, whereas the more general term “ice maker appliance” includes such appliances as well as appliances with diverse capabilities in addition to making ice, such as a refrigerator appliance equipped with an ice maker, among other possible examples.

The ice making assembly 200 may include a carrier or carriage 206 which is rotatable between a first position and a second position and a cartridge 208 which is removably mountable in the carriage 206. For example, the cartridge 208 may be removed and interchanged with a different cartridge 208 and/or a mold body 210 of the cartridge 208 may be interchanged with another mold body 210. For example, the mold body 210 may be removably received in a frame 209 of the cartridge 208. Thus, in various embodiments, the mold body 210 may be releasably received in the carriage 206 and/or cartridge 208. The cartridge 208 may be rotatable between a first position and a second position, e.g., the entire cartridge 208 may be rotatable with the carriage 206 between the first position and the second position when the cartridge 208 is releasably received in the carriage 206. In some embodiments, the rotation between the first position and the second position may be between about ninety degrees (90°) and about one hundred and seventy degrees (170°), such as between about one hundred and thirty degrees (130°) and about one hundred and sixty degrees (160°), such as about one hundred and fifty degrees (150°).

In some embodiments, e.g., as illustrated, the fill cup 222 may be connected to the carriage 206 and may be rotatable with the carriage 206. Accordingly, the ice making assembly 200 may be overall more vertically compact (e.g., as compared to a stationary fill cup design), which provides additional room below the ice making assembly 200, e.g., within icebox 150, such as may be used for a larger ice storage bin.

The cartridge 208 may include the mold body 210 and one or more ejectors 238. The mold body 210 may define one or more chambers or cavities 226 for formation of an ice piece 1000 therein and the ejector 238 may be positioned adjacent to the mold body 210. In some embodiments, the mold body 210 may be interlocked with the ejector 238. The ejector 238 may be configured to push the ice piece 1000 out of the cavity 226 as the cartridge 208 (e.g., the carriage 206 with the cartridge 208 releasably received therein) rotates between the first position and the second position. The mold body 210 may be constructed from a flexible or resilient material, such as silicone rubber. Thus, the mold body 210 may deform when pushed by the ejector 238 to aid in removal of the ice pieces 1000 from the mold body 210.

Turning briefly to FIGS. 10-16, the cartridge 208 is shown removed from the remainder of the ice making assembly 200, e.g., removed the carriage 206, in FIG. 10. FIG. 11 illustrates the remainder of the ice making assembly 200 with the cartridge 208 removed, FIG. 12 illustrates the carriage 206 in isolation, and FIGS. 13-16 provide various views of an exemplary cartridge 208 by itself, e.g., separated and apart from the remainder of the ice making assembly 200.

The cartridge 208 may be rotatable between a first position, e.g., a home position or fill position, (shown in FIGS. 4, 5, 6-8, and 19) and a second position, e.g., a complete harvest position in which ice pieces 1000 may be collected, e.g., harvested, from the mold body 210 (shown in FIG. 20). In the first position (e.g., fill position), mold body 210 can be filled with water from the water supply line 202. For example, a valve (not shown) can be activated by controller 164 as part of an ice making process to provide the appropriate amount of water to flow into the mold body 210 when the cartridge 208 with the mold body 210 therein is in the upper position. In the complete harvest position, the one or more ice pieces 1000 are fully ejected from the mold body 210. Ice pieces 1000 may be, e.g., ejected into an ice bin. Additionally, the cartridge 208 may be rotatable to a plurality of various partial harvesting positions between the first or fill position and the second or complete harvesting position.

A motor 216 operated by controller 164 is used to rotate the carriage 206 (and cartridge 208 releasably received therein) between the first position (e.g., fill position) and the second position (e.g., complete harvest position). For example, motor 216 may drive gears 244 to rotate the carriage 206 about an axis of rotation A-A (FIG. 12) between the first and second positions as desired. The direction of rotation of, e.g., a shaft (not shown) from motor 216 may be used to control the direction of rotation of gears 244, and therefore carriage 206, as determined by controller 164. The carriage 206 may be received between, and rotatable relative to, a left bracket 304 on one side of the carriage 206 and a right bracket 306 on an opposite side of the carriage 206. In some embodiments, a single unitary bracket may be provided to which the carriage 206 is mounted on both sides of the carriage 206.

As mentioned, the cartridge 208 may further include one or more ejectors 238 positioned adjacent to mold body 210. The ejector(s) 238 may be rotatable with the carriage 206 and cartridge 208 between the first position and the second position. As will be explained, the ejectors 238 are configured to push ice pieces 1000 out of mold body 210 during rotation between the first position and the second position. More particularly, the ejectors 238 are configured to move between a retracted position (see, e.g., FIGS. 4, 5, 6, 7, 10, 13, 14, 16, and 19) and an extended position (shown in FIG. 20). Ejectors 238 move from the retracted position to the extended position as cartridge 208 is moved from the first position (e.g., fill position) to the second position (e.g., complete harvest position), respectively. As may be seen in FIG. 20, and as will be further described below, the mold body 210 may be formed at least partly from a flexible material, and such flexible material of the mold body 210 may deform when the ejector 238 pushes the ice piece 1000 out of the cavity 226.

For this exemplary embodiment, movement of ejectors 238 is determined by a cam 218, e.g., the ice making assembly 200 may include one or more cams 218, and each cam 218 may be in mechanical communication with one respective ejector 238. More particularly, a terminal end 240 (see, e.g., FIG. 14) of ejector 238 includes a cam follower or wheel 242 that rides along an arcuate path 220 defined by cam 218. The arcuate path 220 determines the position of ejector 238 as the cartridge rotates from the first position to the second position.

After mold body 210 has been filled with an appropriate amount of water as previously described, the liquid water is allowed to freeze. During the filling and freezing process, the cartridge is maintained in the first position, e.g., mold body 210 remains in the first position and ejector 238 remains in the retracted position. In one exemplary aspect of the invention, water may be filtered to remove particulates and may be cooled along a controlled temperature and time profile to provide clearer ice. Temperature (as measured by one or more sensing devices, e.g., sensing device 215 as illustrated in FIG. 27) may be monitored so that, e.g., controller 164 may determine when the liquid water has been converted into ice pieces 1000.

After a determination has been made that the liquid water has frozen to form ice pieces 1000, controller 164 is configured and operable to activate motor 216 to begin rotation of the carriage 206 (and, consequently, the cartridge 208 therein). As the cartridge 208 rotates about axis of rotation A-A, ejector 238 is urged to the extended position. As the cartridge 208 rotates, ejector 238 moves along a direction perpendicular to axis of rotation A-A (e.g., a radial direction). Rotation forces ejector 238 to so move because cam follower 242 is riding on acuate path 220.

While rotation of the cartridge 208 continues, ejector 238 begins to deform flexible mold body 210. Continued rotation increases the movement of ejector 238 and the deformation of mold body 210. Ice pieces 1000 are also rotated and are forced to move in the same direction as ejector 238 by the pressing of ejector 238. As the cartridge 208 reaches the second position shown in FIG. 20, ejector 238 reaches the extended position so as to force ice pieces 1000 to be fully ejected from mold body 210. The cartridge 208 may also include one or more biasing elements, e.g., leaf springs 230, in mechanical communication with the ejector 238. The biasing element(s) may be configured to urge the ejector from the extended position to the retracted position, e.g., the biasing elements may be compressed as ejector 238 is extended and then urge ejector 238 back to its retracted position when the carriage 206 (and cartridge 208 therein) rotates back to the first position.

In some embodiments, the cartridge 208 may include a latch, and the latch may releasably engage the carriage 206 while the cartridge 208 is received in the carriage 206. As may be seen in FIGS. 6 and 7 for example, the cartridge 208 may include one or more latch pistons 212, such as two latch pistons 212 as in the illustrated exemplary embodiment, which are releasably engaged with through holes 228 (see, e.g., FIGS. 10-12) formed through opposing side walls 224 of the carriage 206. The latch pistons 212 may each include a tip 213 (see, e.g., FIGS. 13-15) which is sized to extend into a corresponding through hole 228 and thereby engage the latch piston 212 with the through hole 228 (e.g., based on the outer diameter of the tip 213 less than the inner diameter of through hole 228). The latch pistons 212 may be movable, e.g., linearly, such as generally along a direction perpendicular to the vertical direction V, between an engaged position (e.g., FIGS. 6 and 7) where the latch pistons 212 are each received in a respective one of the through holes 228 and a release position in which the latch pistons 212 move away from the side walls 224 of the carriage 206, such as towards each other as in the illustrated exemplary embodiment. For example, the latch pistons 212 may be coupled to an actuator 214, e.g., which may be manually actuated, such as by pinching by a user, in order to disengage the latch pistons 212 from the side walls 224 of the carriage 206 and thereby permit removal of the cartridge 208 from the carriage 206. Thus, the cartridge 208 may be releasably received in the carriage 206 in that the cartridge 208 is held in the carriage 206 by engagement of the latch pistons 212 with the side walls 224 of the carriage 206, and the cartridge 208 may be releasable by actuating, e.g., manually pinching, the actuator 214 to pull the latch pistons 212 out of the through holes 228 and thereby disengage the cartridge 208 from the carriage 206, permitting removal of the cartridge 208 from the carriage 206.

As may be seen, e.g., in FIGS. 8 and 9, the ice making assembly 200 may include a duct 320 configured to receive a flow of chilled air 800 (FIG. 9), e.g., from an evaporator (e.g., as discussed below in reference to FIG. 33) of the refrigerator appliance 100 or another suitable chilled air source (such as a dedicated ice making evaporator, e.g., in some refrigerator embodiments and/or embodiments where the ice making assembly 200 is provided in a stand-alone ice making appliance). The duct 320 may be further configured to direct the flow of chilled air 800 to or towards the mold body 210.

The duct 320 may extend from an inlet 322 to an outlet 324. The inlet 322 may be configured to sealingly mate with a conduit (not shown) which extends from a mechanical compartment (such as mechanical compartment 62) or freezer chamber or other location to provide fluid communication from an evaporator to the duct 320 whereby the duct 320 receives the flow of chilled air 800 from the evaporator. For example, the conduit may extend through a wall of the icebox 150, such as an outlet of the conduit may be positioned at the wall of the icebox 150 and the inlet 322 of the duct 320 may connect to the outlet of the conduit, e.g., sealingly mate to the outlet as mentioned, at the wall of the icebox 150 (see, e.g., FIG. 4).

The outlet 324 of the duct 320 may be positioned above the mold body 210 (e.g., when the mold body 210 is received in the cartridge 208 and the cartridge 208 is, in turn, received in the carriage 206). The ice making assembly 200 may further include a hood 328 coupled to the duct 320 at the outlet 324 of the duct 320, such as over the outlet 324, and the hood 328 may be angled downward (such as at an angle oblique to the vertical direction V) to direct the flow of chilled air 800 from the outlet 324 of the duct 320 towards the mold body 210.

In some embodiments, e.g., as may be seen in the section view illustrated in FIG. 9, the duct 320 may include a plurality of diverters therein. Each diverter of the plurality of diverters may extend to or towards the outlet 324, such that each diverter directs a portion of the flow of chilled air 800 to a corresponding portion of the mold body 210, e.g., the corresponding portion of the mold body 210 may be the portion of the mold body 210 which is downstream of the respective diverter along the direction of the flow of chilled air 800. The diverters may be staggered, such that each successive diverter along the direction of flow of the chilled air 800 redirects a generally equivalent portion of the flow of chilled air 800 to each section of the mold body 210. For example, each diverter may define a length, such as from a first end oriented into the flow of chilled air 800 to a second end of the diverter at the outlet 324 of the duct 320. The length of each diverter may be greater than the length of the immediate upstream diverter, such as the length of each diverter may increase by the same amount relative to each prior diverter (“prior” meaning upstream with respect to the flow of chilled air 800 through the duct 320), thereby providing a generally equal flow of chilled air 800 to each portion of the mold body 210. As illustrated in FIG. 9, in some embodiments, the plurality of diverters may include (in serial flow order along the direction of the flow of chilled air 800) a first diverter 250, a second diverter 252, a third diverter 254, and a fourth diverter 256. The first diverter 250 may the shortest diverter of the plurality of diverters, and the fourth diverter 256 may be the longest diverter of the plurality of diverters. For example, the second diverter 252 may be longer than the first diverter 250 by an amount, the third diverter 254 may be longer than the second diverter 252 by approximately the same amount, and the fourth diverter 256 may also be longer than the third diverter 254 by approximately the same amount.

In some embodiments, the mold body 210 may be removable from the cartridge 208. For example, the mold body 210 may be interchangeable with another mold having a different number, shape, and/or size of cavities 226 therein, e.g., for making various types of ice pieces 1000 as may be desired, such as for different beverages or other purposes. For example, as may be seen in FIGS. 16 and 17, the mold body 210 may include one or more tabs 260 which are releasably receivable in corresponding slots 262 in the cartridge 208, such as in one of the ejectors 238. As mentioned, the mold body 210 may be formed from a resilient, flexible material such as silicone rubber. Thus, the tabs 260 of the mold body 210 may be inserted into the slots 262 in the ejectors 238 by pressing the tabs 260 into the slots 262, e.g., through a relatively narrow top opening of each slots 262 which compresses the resilient, flexible material of the tab 260 and into a wider bottom portion of the slot 262 into which the resilient, flexible material of the tab 260 expands to retain the tab 260 in the slot. Similarly, the tabs 260 of the mold body 210 may be removed from the slots 262 in the ejectors 238 by pulling the tabs 260 from the slots 262, e.g., with sufficient force to deform the resilient, flexible material of the tab 260 as the tab 260 is drawn through the narrower upper portion of the slot 262 and out of the slot 262. In some embodiments where the mold body 210 includes tabs 260 engaged in slots 262, the retraction of the ejectors 238 (e.g., as urged by biasing elements, e.g., springs 230) may promote returning the mold body 210 to the original shape, e.g., re-forming the cavities 226 therein, such as the ejector 238 may push the mold body 210 out of the original shape as the ejector 238 extends and then the ejector 238 may pull the mold body 210, via the tabs 260, back into the original shape as the ejector 238 retracts.

In some embodiments, the carriage 206 may include a first knob 264 (FIG. 18) thereon, such as projecting outward from an outer surface of one of the side walls 224 of the carriage 206, and a second knob 266 (FIG. 23), e.g., projecting outward from an outer surface of the other of the side walls 224 of the carriage 206. As may be seen in FIG. 23, the second knob 266 may have a circular cross-sectional shape, e.g., to permit the carriage 206 to rotate relative to an adjoining stationary portion of the ice making assembly 200. For example, second knob 266 may have a generally annular shape, e.g., a rounded, such as circular, overall shape with a central aperture. The second knob 266 may interact with a post (not shown) on the left bracket 304, such as the post on the left bracket 304 may be received within the central aperture of the second knob 266. Accordingly, the second knob 266 and left bracket 304 may cooperatively provide a supporting bearing that allows rotation around a horizontal axis (e.g., axis A-A noted in FIG. 12). As may be seen in FIG. 18, the first knob 264 may have at least one flat side (e.g., may have a disco rectangular cross-sectional shape, or may have a truncated circular cross-sectional shape, e.g., as in the illustrated exemplary embodiment, or other combinations of curvilinear sides and flat sides), and one of the gears 244 may be mounted to the carriage 206 at the second knob 264, whereby rotation of the gear 244 driven by the motor 216 is transferred to the carriage 206 via the first knob 264. In FIG. 18, the right bracket 306 is omitted to more clearly show the positions of the motor 216, gears 244, and second knob 266.

As described above, such rotation of the carriage 206 provides ejection of the ice pieces 1000 from the mold body 210. The carriage 206 may be rotatable between a first (“fill”) position (FIG. 19) and a second (“complete harvest”) position (FIG. 20). As may be seen in FIGS. 19 and 20, the cam follower 242 rides along the arcuate path 220 defined by cam 218 as the carriage 206 and cartridge 208 rotate between the fill position and the complete harvest position. The arcuate path 220 may be a compound curve, such as the arcuate path 220 may include a first portion 221 which has a decreasing radius such that the ejector 238 moves radially inward (e.g., towards the axis of rotation A-A indicated in FIG. 12) as the follower 242 moves along the first portion 221 of the arcuate path 220 from the fill position. The arcuate path 220 may also include a second portion 225 which defines a constant radius, e.g., a circular arc, such that the radial position of the ejector 238 is maintained as the follower 242 moves along the second portion 225 of the arcuate path 220, e.g., as the rotation continues towards the complete harvest position. The compound curved arcuate path 220 may also include an inflection point 223 where the first and second portions 221, 225 adjoin each other. As will be described further below, the ice making assembly 200 may also include a sweep assembly 290, and the sweep assembly 290 may ride on the first portion 221 of the arcuate path 220 as the follower 242 rides on the second portion 225 of the arcuate path 220.

The ice making appliance 200 may further include a sweep assembly 290. The sweep assembly 290, such as at least a wedge 292 thereof, may be configured to move across the mold body 210, e.g., across a top surface of the mold body 210 (“top” referring to the orientation of the mold body 210 when received in the cartridge 208, the cartridge 208 is received in the carriage 206, and the carriage 206 is in the first position), when the carriage 206 rotates from the first position to the second position. As may be seen, e.g., in FIGS. 19 and 20, the sweep assembly 290 may include a wedge 292 with one or more wedge wheels or followers 294 mounted thereto. As may be seen in FIGS. 20 and 21, the wedge 292 may assist with harvesting ice pieces 1000 from the mold body 210, such as by leveraging the ice pieces 1000 out of the cavities 226. In particular, as the carriage 206 (with the cartridge 208 mounted therein) continues to rotate towards the complete harvest position as described above, e.g., when the cam follower 242 of the ejector 238 rides along the second portion 225 of the arcuate path 220, the follower 294 of the wedge 292 may ride along the first portion 221 of the arcuate path 220, such that the decreasing radius of the first portion 221 pushes the follower 294 and the wedge 292 therewith radially inward as the carriage 206 rotates to the complete harvest position. For example, the followers 294 of the sweep assembly 290 are illustrated in FIG. 22 in a position where the followers 294 have just reached a first end of each respective cam 218 while travelling towards the second position. The sweep assembly 290 may thus sweep across the frame 209 and mold body 210 of the cartridge 208 while rotating to the complete harvest position, such that the wedge 292 aids in removal of the ice pieces 1000 from the mold body 210. The sweep assembly 290 may also include one or more biasing elements 296, e.g., compression springs, which are configured to urge the wedge 292 back to the fill position after the carriage 206 rotates far enough towards the fill position from the complete harvest position for the followers 294 on the wedge 292 to clear the cam 218.

As may be seen, e.g., in FIGS. 6, 11, and 23, the ice making assembly may include a first stop 300 and a second stop 302 on the carriage 206. As may be best seen in FIG. 23, when the carriage 206 (and the cartridge 208 mounted therein) reach the second position, the stops 300 and 302 may abut the left bracket 304 and right bracket 306, such as may abut stops (not shown) on each respective bracket 304 and 306 and may thereby prevent or limit over rotation of the carriage 206 beyond the complete harvest position.

In some embodiments, the plurality of ejectors 238 may be linked by a rod 232, whereby the plurality of ejectors 238 generally move together, e.g., between the first position (fill position) and the second position (complete harvest position). The ice making assembly 200 may further include one or more springs 230, such as leaf springs, which engage rod 232 to urge the rod 232, and each of ejectors 238 with it, downward to return to the fill position and re-form the mold cavities 226 (e.g., the flexible material of the mold body 210 returns to its original shape) when the carriage 206 and cartridge 208 rotate back to the fill position. For example, re-forming the mold cavities 226 may permit a subsequent fill of liquid water into the mold cavities 226 to form more ice pieces 1000 therein, e.g., in a subsequent cycle of the ice making assembly 200. The springs 230 may be formed of any suitable material, such as a resilient plastic material.

Referring again to FIG. 23, the ice making assembly 200 may also include a feeler arm 270 which is rotatably mounted on the left bracket 304 and right bracket 306. The feeler arm 270 may be rotatable relative to the left bracket 304 and the right bracket 306. As may be seen, e.g., in FIGS. 4 and 5, the feeler arm 270 may be positioned generally at a front of the ice making assembly 200 and may be configured to extend, e.g., downward, into an ice storage volume, such as may be defined in an ice storage bin (not shown) below the carriage 206 while the carriage 206 is in the first position. As will be described in further detail, the feeler arm 270 may thus be positioned and configured to detect a fill level of the ice storage bin, such as the feeler arm 270 may be configured to detect when the ice storage bin has reached a predetermined level, e.g., height, of ice therein which corresponds to a full status of the ice storage bin, while the carriage 206 is in the first position.

As may be seen, e.g., in FIG. 23, the feeler arm 270 may be attached, e.g., coupled, to a lever 272. The lever 272 may engage with and ride on a rib 274 on carriage 206 as the carriage rotates to the second position. The lever 272 may be configured to rotate the feeler arm upwards as the carriage rotates from the first position to the second position, e.g., engagement of the lever 272 with the rib 274 may rotate the feeler arm 270 upwards, allowing harvested ice pieces 1000 to pass below the feeler arm 270 and into an ice storage bin. When the carriage 206 returns to the fill position, the lever 272 may slide off of the rib 274 on the carriage 206, thereby permitting the feeler arm 270 to rotate downward. When the feeler arm 270 encounters ice pieces 1000 before rotating all the way downward, the full ice storage bin may be thereby detected.

Turning now to FIG. 24 and FIG. 25, the feeler arm 270 may include a tab 276 on the feeler arm 270. When the feeler arm 270 travels all the way down to the fill position, e.g., after a harvest operation and to the position illustrated in FIG. 25, the tab 276 on the feeler arm 270 may engage (e.g., close) a switch 278. When the switch 278 is closed after the harvest operation, a subsequent cycle of the ice making assembly 200 may be initiated. The ice making assembly 200 may further include a biasing element, e.g., spring 280 (FIG. 26), which is connected to the feeler arm 270 and to one of the left and right brackets 304 and 306. The biasing element 280 may be configured to urge feeler arm 270 downward, such that once the lever 272 (FIG. 23) rides off of the rib 274 on the carriage 206, the feeler arm 270 is urged back to the home (down) position, to close the switch 278, unless the downward travel of the feeler arm 270 is obstructed, e.g., by ice pieces 1000 in a full ice storage bin as mentioned above.

The harvest operation may be initiated in response to one or more sensing device readings which indicate the liquid water in the mold body 210 has converted to ice, e.g., frozen. As may be seen for example in FIG. 27, the ice making assembly 200 may include a temperature sensing device 215, e.g., thermistor, which extends through carriage 206 into a slot 298 in the cartridge 208, such that the temperature sensing device 215 is thereby positioned proximate to the mold body 210 and cavities 226 thereof, permitting the temperature sensing device 215 to measure a temperature indicative of the state of water in the mold body 210, e.g., whether the water is liquid or frozen solid. When the temperature measured by the temperature sensing device 215 indicates ice pieces 1000 have been formed, the harvest operation, e.g., rotation of the carriage 206 and cartridge 208 therein to (or towards, such as at least partially to) the complete harvest position from the fill position as described above, may be initiated, e.g. by the controller 164 in response to a signal from the temperature sensing device 215, the signal indicative of the temperature measured by sensing device 215 having reached a predetermined threshold temperature for ice formation, such as the measured temperature having been at or below the predetermined threshold temperature for at least a minimum time. In additional embodiments, a non-contact temperature sensing device, e.g., an infrared temperature sensing device, may be used as well as or instead of the temperature sensing device 215.

In some embodiments, the ice making assembly 200 may include one or more position sensing devices. For example, the position sensing devices may be Hall effect sensing devices. Referring now to FIGS. 28 and 29, a magnet 340 may be provided in the carriage 206, and one or more position sensing devices, e.g., Hall effect sensing devices, may be located on a stationary (e.g., non-rotating) component of the ice making assembly 200, such as the bracket, e.g., right bracket 306 as illustrated in FIG. 29. Thus, the position sensing devices may respond to the magnet 340 in the carriage 206, as will be understood by those of ordinary skill in the art, and thereby determine whether the carriage 206 is in a respective position corresponding to the location of the sensing device.

In particular, as illustrated in FIG. 29, a first position sensing device 344 and a second position sensing device 342 may be provided on a circuit board (e.g., a Printed Circuit Board “PCB”) 346 mounted to the right bracket 306. The first position sensing device 344 may be positioned and configured to detect or determine whether the carriage 206 is in or near the first position, e.g., the fill position, and the first position sensing device 344 may therefore be referred to as a fill position sensing device. The second position sensing device 342 may be positioned and configured to detect or determine whether the carriage 206 is in or near the second position, e.g., the complete harvest position, and the second position sensing device 342 may therefore be referred to as a complete harvest position sensing device. As used herein, the carriage 206 is “near” one of the first position or the second position when the carriage 206 is within 95% of the total distance of travel from the first position to the second position of the respective position, e.g., the carriage 206 may be near the second position when the carriage 206 has travelled at least 95% of the distance from the first position to the second position, or, in other words, when the carriage is within 5% of the second position.

Referring now to FIG. 30, the sweep assembly 290 may include a wall 291 which defines a catch basin in the sweep assembly 290. In particular, the wall 291 may be positioned and oriented to catch or obstruct liquid water, e.g., splashed or spilled water such as from the fill cup 222, from travelling to a storage bin below the ice making assembly 200 (such as a removable bin which may be positioned in the ice making chamber 154 (see, e.g., FIG. 4) below the ice making assembly 200. As may be seen for example in FIG. 31, such water may collect in or on the sweep assembly 290 and may freeze, resulting in the formation of undesired ice pieces (which may also be referred to as ice clogs) outside of the mold body 210, such as a first undesired ice piece 1002 and/or second undesired ice piece 1004. Such undesired ice pieces may interfere with or impede movement of the ice making assembly 200, such as movement, e.g., rotation, of the carriage 206 and/or sweep assembly 290. For example, such undesired ice pieces may prevent the ice making assembly 200 from reaching the second position, e.g., complete harvest position. When the ice making assembly 200, e.g., carriage 206 and/or sweep assembly 290 thereof, does not reach the second position, the ice pieces 1000 may not be ejected from the mold body 210. Thus, an overfill may occur during a subsequent ice making cycle.

Turning now to FIG. 32, a flow of air 810 may be directed to a portion of the ice making assembly 200 (such as carriage 206 and/or sweep assembly 290), e.g., to remove any undesired ice pieces which may be present, e.g., in or on such portion of the ice making assembly 200. In particular, the flow of air 810 may be distinct from the flow of chilled air 800 (see, e.g., FIG. 9) which is provided for ice formation in that the flow of air 810 may be colder (and thereby drier, e.g., lower humidity and/or moisture content) and/or faster than the flow of chilled air 800. For example, the low moisture content and/or high flow rate of the flow of air 810 may promote vaporization of undesired ice, e.g., 1002 and/or 1004, such as the flow of air 810 may induce a non-spontaneous phase change, e.g., vaporization, such as sublimation of the ice directly from solid form to vapor form entrained in the flow of air 810, in the undesired piece(s) 1002 and/or 1004.

FIG. 33 provides a schematic view of the refrigerator appliance 100, in particular the sealed cooling system 60 thereof. As illustrated in FIG. 33, refrigerator appliance 100 includes a mechanical compartment 62 that at least partially contains components for executing a known vapor compression cycle for cooling air. The components include a compressor 64, a heat exchanger or condenser 66, an expansion device 68, and an evaporator 70 connected in series and charged with a refrigerant. Evaporator 70 is also a type of heat exchanger which transfers heat from air passing over the evaporator to refrigerant flowing through evaporator 70 thereby causing the refrigerant to vaporize. As such, cooled air C is produced and configured to refrigerate at least one chamber, e.g., chambers 122 and 124 and/or ice making chamber 154, of refrigerator appliance 100. The cooled air C may be directed to the chamber(s) 122, 124, and/or 154 by a fan 74.

From evaporator 70, vaporized refrigerant flows to compressor 64, which operates to increase the pressure of the refrigerant. This compression of the refrigerant raises its temperature, which is lowered by passing the gaseous refrigerant through condenser 66 where heat exchange with ambient air takes place so as to cool the refrigerant. A fan 72 is used to pull air across condenser 66, as illustrated by arrows A, so as to provide forced convection for a more rapid and efficient heat exchange between the refrigerant and the ambient air.

Expansion device 68 further reduces the pressure of refrigerant leaving condenser 66 before being fed as a liquid to evaporator 70. Collectively, the vapor compression cycle components in a refrigeration circuit, associated fans, and associated compartments are sometimes referred to as a sealed refrigeration system operable to force cold air through refrigeration chambers 122 and 124. The refrigeration system 60 depicted in FIG. 33 is provided by way of example only. It is within the scope of the present invention for other configurations of the refrigeration system to be used as well. For example, fan 74 may be repositioned so as to push air across evaporator 70, dual evaporators may be used with one or more fans, and numerous other configurations may be applied as well.

Referring now generally to FIGS. 34 and 35, the methods 600 and/or 700 may be interrelated and/or may have one or more steps from one of the methods 600 and 700 combined with the other method 600 or 700. Thus, those of ordinary skill in the art will recognize that the various steps of the exemplary methods described herein may be combined in various ways to arrive at additional embodiments within the scope of the present disclosure.

FIGS. 34 and 35 depict steps in a particular order for purpose of illustration and discussion. Those of ordinary skill in the art, using the disclosures provided herein, will understand that (except as otherwise indicated) methods 600 and 700 are not mutually exclusive. Moreover, the steps of the methods 600 and 700 can be modified, adapted, rearranged, omitted, interchanged, or expanded in various ways without deviating from the scope of the present disclosure.

Furthermore, the skilled artisan will recognize the interchangeability of various features from different embodiments. Similarly, the various method steps and features described, as well as other known equivalents for each such methods and feature, can be mixed and matched by one of ordinary skill in this art to construct additional systems and techniques in accordance with principles of this disclosure. Of course, it is to be understood that not necessarily all such objects or advantages described above may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the systems and techniques described herein may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

Turning now to FIG. 34, an embodiment of the present disclosure may include a first method of operating an ice maker appliance, such as the exemplary ice maker assembly 200 of the refrigerator appliance 100 described above.

As shown in FIG. 34, method 600 may include directing liquid water to the mold cavities, e.g., as indicated at (610) in FIG. 34. For example, for the ice maker assembly 200 described above, the controller 164 may operate a valve (not shown) to permit water to flow from the water supply line 202 and into the mold cavities 226.

After directing the liquid water to the mold cavities, the method 600 may include initially operating the motor of the ice maker assembly to rotate the mold body from an initial position and between the fill position and the complete harvest position, e.g., as indicated at (620) in FIG. 34. For example, the controller 164 may initially operate motor 216 to rotate the carriage 206 and, thus, the mold body 210, from its initial position, which may be the fill position or the complete harvest position. Thereafter, the method 600 may include (630) determining a rotational status of the mold body based on whether a signal indicating rotation of the mold body was emitted by a sensing device of the ice maker assembly.

For example, controller 164 may be operatively or communicatively coupled or connected to one or more sensing devices, such as the fill position sensing device 344 and/or the complete harvest position sensing device 342. As such, in some embodiments, the fill position sensing device 344 and/or the complete harvest position sensing device 342 emit a signal that may be received by controller 164 in response to one or both of fill position sensing device 344 and complete harvest position sensing device 342 sensing rotational movement of the carrier 206/mold body 210, e.g., rotational movement may be inferred when the position sensing device 342, 344 detects that the carriage 206 (and thus the mold body 210 therein) has reached or is near the position opposite the initial position (where “near” a position is to be understood as, e.g., within 5% of the stated position, as described above).

Upon receiving the signal emitted by sensing device(s) 342, 344, controller 164 may determine that the mold body 210 is rotating (e.g., as mentioned, when the mold body 210 starts at one of the fill position or the complete harvest position, the controller 164 may then determine, e.g., infer, that the mold body 210 is rotating when the respective position sensing device detects the mold body 210 in or near the other of the fill position of the complete harvest position). Additionally, when carrier 206/mold body 210 is jammed/not rotating, sensing device(s) 342, 344 may not sense rotational movement of the carrier 206/mold body 210 (e.g., where the sensing device(s) 342 and 344 are Hall effect sensors, when the corresponding sensing device does not detect the carriage and mold body reaching at or near the position opposite the initial position) and, thus, does not emit the signal to be received by controller 164. As such, controller 164 may determine that the mold body 210 is not rotating when controller 164 does not receive the signal from sensing device(s) 342, 344, such as not receiving the signal from sensing device(s) 342, 344 within a predetermined length of time after initially operating motor 216.

Additionally, the method 600 may include selecting a length of time for which to operate the motor based on the determined rotational status of the mold body, e.g., as indicated at (640) in FIG. 34. For example, in some embodiments, upon determining that the carrier 206/mold body 210 is rotating at (630), controller 164 may select a first predetermined length of time for which to continue operating the motor 216. For example, when the carrier 206/mold body 210 initially rotates from the fill position to harvest the ice pieces 1000, the first predetermined length of time is the length of time after determining that the carrier 206/mold body 210 is near, e.g., within 5% of, the complete harvest position in which the carrier 206/mold body 210 reaches the complete harvest position. That is, the first predetermined length of time may be the time in which it is expected that the carriage 206 and/or mold body 210 will travel the remaining distance from the initial position to the other of the fill position or the complete harvest position, such as the remaining 5% of the distance between the fill position and the complete harvest position, e.g., when the position sensing device 342, 344 is located near the corresponding position as described above. Likewise, after attempting to harvest the ice pieces, when the carrier 206/mold body 210 initially rotates from the complete harvest position to the fill position to receive more water within the mold cavities 226, the first predetermined length of time is the length of time after determining that the carrier 206/mold body 210 is rotating in which carrier 206/mold body 210 reaches the fill position. Moreover, in some embodiments, upon determining that the mold body 210 is not rotating at (630), controller 164 may select a second predetermined length of time for which to continue operating the motor 216. The second predetermined length of time may be different from, e.g., shorter than, the first predetermined length of time, such as to inhibit or avoid overloading the motor 216. As will be described below, controller 164 may perform an ice maker assembly fault operation in response to controller 164 not receiving an emitted signal from sensing device(s) 342, 344 during the second predetermined length of time.

Thereafter, the method 600 may include operating the motor for the selected length of time, e.g., as indicated at (650) in FIG. 34. For example, after selecting the length of time at (640), controller 164 may operate the motor 216 for the selected length of time, e.g., for the first predetermined length of time or the second predetermined length of time.

Furthermore, in some embodiments, after selecting the second predetermined length of time and the second predetermined length of time has passed, the method 600 may include performing an ice maker appliance fault operation in response to determining that the signal indicating rotation of the mold body was not emitted by the sensing device during the during the second predetermined length of time, e.g., as indicated at (660) in FIG. 34. Specifically, controller 164 may determine that the signal indicating rotation of the carrier 206/mold body 210 was not emitted by the sensing device(s) 342, 344 during the second predetermined length of time and, thus, that the carrier 206/mold body 210 is rotationally jammed. Thereafter, controller 164 may perform the ice maker appliance fault operation in response to determining that the signal indicating rotation of the carrier 206/mold body 210 was not emitted by the sensing device 342, 344 during the second predetermined length of time.

The ice maker appliance fault operation may be an operation performed by controller 164 in an attempt to clear the rotational jam of the carrier 206/mold body 210. As such, the fault operation may include controller 164 operating the motor 216 to rotate the carrier 206/mold body 210 back to the initial position, either the fill position or the complete harvesting position. For example, controller 164 may operate the motor 216 for a predetermined length of time, such as the first predetermined length of time. After the motor 216 has been operated for the first predetermined length of time, e.g., the carrier 206/mold body 210 has returned to the initial position, controller 164 may operate the motor 216 to rotate the carrier 206/210 from the initial position for a second time. Thereafter, controller 164 may again determine the rotational status of the carrier 206/mold body 210 based on whether the signal indicating rotation of the carrier 206/mold body 210 was emitted by the sensing device 342, 344. For example, controller 164 may determine that the mold body 210 is not rotating for a second time, e.g., the carrier 206/mold body 210 is still experiencing the rotational jam, in response to not receiving the signal indicating rotation of the carrier 206/mold body 210 from the sensing device 342, 344. Thereafter, as will be described below, when the controller 164 has determined that the carrier 206/mold body 210 is not rotating for the second time, the controller 164 may perform a control action.

For example, in some embodiments, when performing the control action, controller 164 may initiate a notification to an operator of the ice maker appliance of a fault of the ice maker assembly 200, e.g., displaying the notification on the ice maker appliance and/or to a remote user interface device. For example, the user notification may be displayed on a user interface of the refrigerator appliance 100, such as on display 166 (FIG. 1). In exemplary embodiments where the user notification is also or instead provided on the remote user interface device, the remote user interface device may be any suitable device such as a laptop computer, smartphone, tablet, personal computer, wearable device, smart speaker, smart home system, and/or various other suitable devices. The remote user interface device is “remote” at least in that it is spaced apart from and not physically connected to the ice maker appliance, e.g., the remote user interface device is a separate, stand-alone device from the ice maker assembly which communicates with the ice maker appliance wirelessly, e.g., through various possible communication connections and interfaces such as WI-FI®. The ice maker assembly and the remote user interface device may be matched in wireless communication, e.g., connected to the same wireless network. The ice maker appliance may communicate with the remote user interface device via short-range radio such as BLUETOOTH® or any other suitable wireless network having a layer protocol architecture. Any suitable device separate from the ice maker appliance that is configured to provide and/or receive communications, information, data, or commands from a user may serve as the remote user interface device, such as a smartphone, smart watch, personal computer, smart home system, or other similar device. For example, the remote user interface device may be a smartphone operable to store and run applications, also known as “apps,” and some or all of the method steps disclosed herein may be performed by a smartphone app. For example, the user notification may be or include an email, a text message, and/or other suitable notifications via a remote user interface device.

Additionally, or alternatively, in some embodiments, performing the control action may include the controller 164 operating an air flow component, such as a fan, to apply a flow of air to the mold body 210 for melting ice pieces, e.g., ice pieces 1000, 1002, 1004. Once the air flow component has been operated for a time, the controller 164 may perform a “test” rotational operation of the carrier 206/mold body 210 to see if the rotational jam was resolved by melting the ice pieces.

Additionally, or alternatively, in some embodiments, performing the control action may include operating the valve (not shown) to restrict the flow of liquid water to the mold cavities 226. For example, the controller 164 may operate the valve of the to restrict water flow into the mold cavities 226 from the water supply line 202. As such the mold cavities 226 are not filled with liquid water to be formed into subsequent ice pieces while the rotational jam of the carrier 206/mold body 210 persists.

A second exemplary method of operating an ice maker appliance according to one or more embodiments of the present disclosure is illustrated in FIG. 35. As shown in FIG. 35, the exemplary method 700 may include (710) directing liquid water to the mold cavities, e.g., as described above with respect to (610) of method 600. Thereafter, the method 700 may include (720) initially operating the motor of the ice maker assembly to rotate the mold body from an initial position and between the fill position and the complete harvest position, e.g., as described above with respect to (620) of method 600.

Additionally, after initially operating the motor, the method 700 may include (730) detecting a rotational jam of the mold body. For example, in some embodiments, when detecting the rotational jam of the carrier 206/mold body 210, controller 164 may receive data from sensing device(s) 342, 344 indicative of the rotational jam of the carrier 206/mold body 210. Thereafter, controller 164 may determine that the carrier 206/mold body 210 is rotationally jammed based on the received sensing device data.

Additionally, the method 700 may include selecting a predetermined length of time for which to operate the motor in response to determining that the mold body is rotationally jammed, e.g., as indicated at (740) in FIG. 35. For example, the controller 164 may select the predetermined length of time for which to operate the motor 216 in response to determining that the carrier 206/mold body 210 is rotationally jammed. The predetermined length of time may be approximately the same as the first predetermined length of time described above with reference to (640) of method 600. Thereafter, the method 700 may (750) operating the motor for the selected predetermined length of time. For example, the controller 164 may operate the motor 216 for the predetermined length of time, e.g., for the first predetermined length of time.

Thereafter, after operating the motor for the selected predetermined length of time, the method 700 may include operating the motor to rotate the mold body toward the initial position of the mold body until the mold body has returned to the initial position, e.g., as indicated at (760) in FIG. 35. For example, the controller 164 may operate the motor 216 to rotate the carrier 206/mold body 210 toward either the initial position, e.g., the fill position or the complete harvesting position, until the carrier 206/mold body 210 has returned to the initial position.

Furthermore, once the mold body has returned to the initial position, the method 700 may include operating the motor to rotate the mold body away from the initial position for a second time, e.g., as indicated at (770) in FIG. 35. For example, the controller 164 may operate the motor 216 to rotate the carrier 206/mold body 210 away from the initial position for a second time. Thereafter, the method 700 may include (780) detecting the rotational jam of the mold body for a second time. For example, as described above with respect to (720), controller 164 may receive data from the sensing device(s) 342, 344 indicative of the rotational jam of the carrier 206/ mold body 210. Thereafter, controller 164 may determine that the carrier 206/mold body 210 is rotationally jammed based on the received sensing device data.

Additionally, the method 700 may include performing an operation associated with clearing the rotational jam of the mold body, e.g., as indicated at (790) in FIG. 35. For example, the controller 164 may perform the operation associated with clearing the rotational jam of the carrier 206/mold body 210. In some embodiments, when performing the operation, the controller 164 may initiate a notification to an operator of the ice maker assembly 200 of a fault of the ice maker assembly 200 similar to method 600 described above. Additionally, or alternatively, in some embodiments, when performing the operation, the controller 164 may operate the air flow component to apply the flow of air to the mold body 210 to melt the ice pieces similar to method 600 described above. Additionally, or alternatively, in some embodiments, when performing the operation, the controller 164 may operate the valve (not shown) to restrict the flow of liquid water to the mold cavities 226 similar to method 600 described above.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A method of operating an ice maker appliance, the ice maker appliance comprising a mold body, a motor coupled to the mold body whereby the motor is operable to rotate the mold body between a fill position and a complete harvest position, and a controller in operative communication with the motor, wherein the mold body receives a fill of liquid water in the fill position and wherein an ice piece is released from the mold body in the complete harvest position, the method comprising:

initially operating, with the controller, the motor of the ice maker appliance to rotate the mold body from an initial position, the initial position comprising one of the fill position or the complete harvest position;

after initially operating the motor, determining, with the controller, a rotational status of the mold body based on whether a signal indicating rotation of the mold body was emitted by a sensing device of the ice maker appliance;

selecting, with the controller, a length of time for which to operate the motor based on the determined rotational status of the mold body; and

operating, with the controller, the motor for the selected length of time.

2. The method of claim 1, wherein selecting the length of time for which to operate the motor based on the determined rotational status of the mold body comprises selecting a first predetermined length of time when the rotational status of the mold body is rotating, and selecting a second predetermined length of time when the rotational status of the mold body is not rotating, the second predetermined length of time different from the first predetermined length of time.

3. The method of claim 1, wherein:

determining the rotational status of the mold body comprises determining, with the controller, that the mold body is rotating in response to determining that the signal indicating rotation of the mold body was emitted by the sensing device; and

selecting the length of time for which to operate the motor comprises selecting, with the controller, a predetermined length of time for which to continue operating the motor in response to determining that the mold body is rotating, whereby the mold body is rotated to one of the fill position or the complete harvest position.

4. The method of claim 1, wherein:

determining the rotational status of the mold body comprises determining, with the controller, that the mold body is not rotating in response to determining that the signal indicating rotation of the mold body was not emitted by the sensing device; and

selecting the length of time for which to operate the motor comprises selecting, with the controller, a predetermined length of time for which to operate the motor whereby an overload of the motor is inhibited.

5. The method of claim 4, further comprising:

operating, with the controller, the motor for the predetermined length of time; and

after the predetermined length of time has passed, performing, with the controller, an ice maker appliance fault operation in response to determining that the signal indicating rotation of the mold body was not emitted by the sensing device during the predetermined length of time.

6. The method of claim 5, wherein performing the ice maker appliance fault operation comprises:

operating, with the controller, the motor to rotate the mold body toward the initial position until the mold body returns to the initial position;

after the mold body returns to the initial position, operating, with the controller, the motor to rotate the mold body from the initial position for a second time;

after operating the motor to rotate the mold bold from the initial position for a second time, determining, with the controller, that the mold body is not rotating for a second time in response to determining that the signal indicating rotation of the mold body was not emitted by the sensing device; and

performing, with the controller, a control action in response to determining that the mold body is not rotating for a second time.

7. The method of claim 6, wherein performing the control action comprises:

initiating, with the controller, a notification to an operator of the ice maker appliance of a fault of the ice maker appliance.

8. The method of claim 6, wherein performing the control action comprises:

operating, with the controller, a fan to provide a flow of air to the mold body for melting the ice piece.

9. A method of operating an ice maker appliance, the ice maker appliance comprising a mold body, a motor coupled to the mold body whereby the motor is operable to rotate the mold body between a fill position and a complete harvest position, and a controller in operative communication with the motor, wherein the mold body receives a fill of liquid water in the fill position and wherein an ice piece is released from the mold body in the complete harvest position, the method comprising:

initially operating, with the controller, the motor of the ice maker appliance to rotate the mold body from an initial position, the initial position comprising one of the fill position or the complete harvest position;

after initially operating the motor, detecting, with the controller, a rotational jam of the mold body; and

performing, with the controller, a first operation associated with clearing the rotational jam of the mold body.

10. The method of claim 9, wherein detecting the rotational jam of the mold body comprises:

receiving, with the controller, sensing device data indicative of a rotational jam of the mold body; and

determining, with the controller, that the mold body is rotationally jammed based on the received sensing device data.

11. The method of claim 9, wherein performing the first operation comprises:

selecting, with the controller, a length of time for which to operate the motor in response to determining that the mold body is rotationally jammed; and

operating, with the controller, the motor for the length of time.

12. The method of claim 11, wherein performing the first operation further comprises:

after operating the motor for the length of time, operating, with the controller, the motor to rotate the mold body toward the initial position until the mold body returns to the initial position; and

after the mold body returns to the initial position, operating, with the controller, the motor to rotate the mold body from the initial position again.

13. The method of claim 12, further comprising:

after operating the motor to rotate the mold body from the initial position again, detecting, with the controller, a rotational jam of the mold body again; and

performing, with the controller, a second operation associated with clearing the rotational jam of the mold body.

14. The method of claim 13, wherein performing the second operation comprises:

initiating, with the controller, a notification to an operator of the ice maker appliance of a fault of the ice maker appliance.

15. The method of claim 13, wherein performing the second operation comprises:

operating, with the controller, a fan to provide a flow of air to the mold body for melting the ice piece.

16. An ice maker appliance, comprising:

a mold body configured to receive a fill of liquid water thereby permitting an ice piece to be formed therein, the mold body rotatable between a fill position, in which the mold body receives the fill of liquid water, and a complete harvest position, in which the ice piece is released from the mold body;

a motor operatively coupled to the mold body, the motor operable to rotate the mold body between the fill position and the complete harvest position;

a sensing device configured to emit a signal indicative of rotation of the mold body; and

a controller operatively coupled to the sensing device and the motor, the controller configured to: initially operate the motor to rotate the mold body; after initially operating the motor, determine a rotational status of the mold body based on whether the signal indicating the rotation of the mold body was emitted by the sensing device; select a length of time for which to continue operating the motor based on the determined rotational status of the mold body; and operate the motor for the selected length of time.

17. The ice maker appliance of claim 16, wherein the sensing device is configured as a Hall effect-based sensing device.