Ice maker
09976786 ยท 2018-05-22
Assignee
Inventors
- Brian J. Beuligman (Evansville, IN, US)
- Scott Daniel Boyd (Cedar Rapids, IA, US)
- Trevor Hawkins (Belle Plaine, IA, US)
- Steven L. Proctor (Evansville, IN, US)
- Chad J. Rotter (Amana, IA, US)
- William C. Montgomery (Owensboro, KY, US)
Cpc classification
Y10T137/7313
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F25C1/25
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25C2700/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25C2600/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25C2500/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
G05D9/00
PHYSICS
F25C2700/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25C2400/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25C2500/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y10T137/7306
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F25C2400/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y10T137/7303
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y10T137/8342
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
G05D9/00
PHYSICS
F25C1/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A stand alone ice making appliance or an ice maker within an appliance is provided including a water inlet, a water inlet valve disposed within the water inlet configured to allow water passage when in an open position and configured to prevent water passage when in a closed position, a reservoir in fluid communication with the water inlet, a water level sensor disposed in the reservoir, and a control unit in electrical communication with the water level sensor and the water inlet valve. The control unit is configured to calculate a fluid flow rate using the time between the water inlet valve opening and the water level sensor communicating when a first predetermined water level has been reached within the reservoir, and use the calculated flow rate to calculate a total water inlet valve open time to fill the reservoir to a second predetermined water level.
Claims
1. An ice making appliance comprising: a water inlet valve configured to allow water passage when in an open position and configured to prevent water passage when in a closed position; a reservoir; a water level sensor, wherein the water level sensor is connected to a reservoir bracket located adjacent the reservoir, the reservoir bracket is connected to the reservoir and the reservoir bracket includes a panel mount surface configured to receive one or more of a recirculation pump connector, a drain pump connector, and a contact sensor connector; a cover slidably engaged with the reservoir bracket, wherein the cover includes a plurality of slidable engagement elements configured to engage a cover mounting flange on the reservoir bracket; and a control unit in electrical communication with the water level sensor and the water inlet valve, wherein one or more times between the water inlet valve opening and the water level sensor communicating when a first predetermined water level has been reached within the reservoir are recorded as one or more recorded times, the control unit being configured to close the water inlet valve at a time based on the one or more recorded times if no signal is received from the water level sensor.
2. The ice making appliance of claim 1, further comprising a water inlet, wherein: the water inlet valve is disposed within the water inlet; and the reservoir is in fluid communication with the water inlet.
3. The ice making appliance of claim 1, wherein the water level sensor is disposed in the reservoir.
4. The ice making appliance of claim 1, wherein: the control unit includes a computer readable storage medium; and the one or more times are recorded on the computer readable storage medium as the one or more recorded times.
5. The ice making appliance of claim 1, wherein the control unit is configured to calculate a fluid flow rate using the time between the water inlet valve opening and the water level sensor communicating when the first predetermined water level has been reached within the reservoir and use the calculated flow rate to calculate a total water inlet valve open time to fill the reservoir to a second predetermined water level.
6. The ice making appliance of claim 5, wherein the first predetermined water level within the reservoir is substantially the same as the second predetermined water level.
7. The ice making appliance of claim 5, wherein the control unit closes the water inlet valve once the total water inlet valve open time has elapsed.
8. An ice making appliance comprising: a water inlet valve configured to allow water passage when in an open position and configured to prevent water passage when in a closed position; a reservoir; a water level sensor; and a control unit in electrical communication with the water level sensor and the water inlet valve; wherein the control unit is configured to calculate a fluid flow rate using the time between the water inlet valve opening and the water level sensor communicating when a first predetermined water level has been reached within the reservoir; and wherein one or more calculated flow rates are recorded as one or more recorded flow rates for one or more initial reservoir fill cycles, the control unit being configured to close the water inlet valve at a time based on the one or more recorded flow rates if no signal is received from the water level sensor during a subsequent reservoir fill cycle.
9. The ice making appliance of claim 8, further comprising a water inlet, wherein: the water inlet valve is disposed within the water inlet; and the reservoir is in fluid communication with the water inlet.
10. The ice making appliance of claim 8, wherein the water level sensor is disposed in the reservoir.
11. The ice making appliance of claim 8, wherein: the control unit includes a computer readable storage medium; and the one or more calculated flow rates are recorded on the computer readable storage medium as the one or more recorded flow rates.
12. The ice making appliance of claim 8, wherein the control unit is configured to use the calculated flow rate to calculate a total water inlet valve open time to fill the reservoir to a second predetermined water level.
13. The ice making appliance of claim 12, wherein the first predetermined water level within the reservoir is substantially the same as the second predetermined water level.
14. The ice making appliance of claim 12, wherein the control unit closes the water inlet valve once the total water inlet valve open time has elapsed.
15. The ice making appliance of claim 8, wherein the water level sensor is connected to a reservoir bracket located adjacent the reservoir.
16. The ice making appliance of claim 15, wherein: the reservoir bracket is connected to the reservoir; and the reservoir bracket includes a panel mount surface configured to receive one or more of a recirculation pump connector, a drain pump connector, and a contact sensor connector.
17. The ice making appliance of claim 16, further comprising a cover slidably engaged with the reservoir bracket, wherein the cover includes a plurality of slidable engagement elements configured to engage a cover mounting flange on the reservoir bracket.
18. A method of filling a reservoir within an ice making appliance, the method comprising: opening a water inlet valve; filling a reservoir to a first predetermined level; sending a signal from a water level sensor to a control unit when the reservoir is filled to the first predetermined level; recording one or more times between the water inlet valve opening and the water level sensor sending the signal as one or more recorded times for one or more initial reservoir fill cycles; closing the water inlet valve at a time based on the one or more recorded times when no signal is received from the water level sensor during a subsequent reservoir fill cycle; calculating a water flow rate from the time between the water inlet valve opening and the water level sensor sending the signal to the control unit; calculating a total time the water inlet valve is to remain open based on the calculated flow rate and a second predetermined water level; and closing the water inlet valve once the total time the water valve is to remain open has elapsed.
19. The method according to claim 18, wherein sending the signal from the water level sensor includes sending the signal from the water level sensor disposed within the reservoir.
20. The method according to claim 18, wherein: the control unit includes a computer readable storage medium; and recording the one or more times as the one or more recorded times includes recording the one or more times on the computer readable storage medium.
21. The method of claim 18, wherein the first predetermined water level is substantially the same as the second predetermined water level.
22. A method of filling a reservoir within an ice making appliance, the method comprising: opening a water inlet valve; filling a reservoir to a first predetermined level; sending a signal from a water level sensor to a control unit when the reservoir is filled to the first predetermined level; calculating a water flow rate from the time between the water inlet valve opening and the water level sensor sending the signal to the control unit; recording one or more calculated flow rates as one or more recorded flow rates for one or more initial reservoir fill cycles; and closing the water inlet valve at a time based on the one or more recorded flow rates if no signal is received from the water level sensor during a subsequent reservoir fill cycle.
23. The method according to claim 22, wherein sending the signal from the water level sensor includes sending the signal from the water level sensor disposed within the reservoir.
24. The method according to claim 22, wherein: the control unit includes a computer readable storage medium; and recording the one or more calculated flow rates as the one or more recorded flow rates includes recording the one or more calculated flow rates on the computer readable storage medium.
25. The method of claim 22, further comprising: calculating the total time the water inlet valve remains open based on the calculated flow rate and a second predetermined water level; and closing the water inlet valve once the total time the water valve remains open has elapsed.
26. The method of claim 25, wherein the first predetermined water level is substantially the same as the second predetermined water level.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(19) Referring now to the discussion that follows and also to the drawings, illustrative approaches to the disclosed systems and methods are shown in detail. Although the drawings represent some possible approaches, the drawings are not necessarily to scale and certain features may be exaggerated, removed, or partially sectioned to better illustrate and explain the present disclosure. Further, the descriptions set forth herein are not intended to be exhaustive or otherwise limit or restrict the claims to the precise forms and configurations shown in the drawings and disclosed in the following detailed description.
(20) According to various exemplary illustrations described herein, a system and method are disclosed. Specifically, an exemplary ice maker, which may be in the form of a standalone appliance, including undercounter, freestanding or counter top, or incorporated into another appliance, such as a refrigerator or freezer appliance. Although the embodiment described below is illustrated as a standalone appliance, the invention should not be limited to such an arrangement.
(21) Turning to the exemplary illustrations,
(22) Referring now to
(23) A contact sensor 108 may be configured within the reservoir 100 and may sense when water within the reservoir 100 reaches a desired height. It is contemplated that the contact sensor 108 may be configured adjacent the reservoir 100 in a variety of locations that may sense or indicate the desired height of the water within the reservoir. The contact sensor 108 may be configured to relay a signal to the control unit 76 located in a cavity of the control housing 70 that isolated from the water. The control unit 76 may then determine the time lapse between opening of the water inlet valve 78 and the signal from the contact sensor 108 representing the desired height of the water within the reservoir 100. This time lapse may be used to calculate a water flow rate of the water flowing through the water supply inlet, using the following formula:
F=Vsn/Tsn
(24) Where:
(25) F=Flow Rate
(26) Vsn=Volume of water in reservoir at the sensor
(27) Tsn=Time to reach the sensor within the reservoir.
(28) The control unit 76 may then use the calculated flow rate to calculate an open water inlet valve 78 time to achieve a predetermined volume of water in the reservoir 100, using the following formula:
T=F*Vd
(29) Where:
(30) T=total time to keep the valve open
(31) F=flow Rate
(32) Vd=total volume of water in reservoir desired.
(33) The water flow rate may be calculated on every fill cycle, adjusting for minor or major changes in a water supply pressure. This may be related to both external water pressure, or internal obstructions, including that a water filter.
(34) It is further contemplated that the contact sensor 108 may be positioned such that it senses a desired volume of water within the reservoir 100 representative of an upper of full condition. In this condition, Tsn and T may be substantially the same, and Vsn and Vd may be substantially the same.
(35) Alternatively, the contact sensor 108 may be attached to a reservoir bracket 110 as shown in
(36) In a further aspect of the disclosure, the time information gathered by the contact sensor 108 or the flow rate information calculated by the control unit 76 may be stored in a computer readable memory configured within the control unit 76. This stored information may be further utilized by the control unit 76 to control subsequent reservoir 100 fill cycles in the case of a contact sensor 108 failure or other situation where the instant time to fill information is not available. Additionally the control unit 76 may use one or more of the recorded data to do, or assisting in doing, one or more of the following: predict harvest cycle times, time to complete the next harvest, time to fill the entire storage bucket, time before filters need to be replaced, time until the next cleaning cycle should be implemented, recalibration of the flow meter and the like.
(37) A further aspect of the disclosure, as shown on
(38) According to yet another aspect of the disclosure, the evaporator plate 90 may be sloped downward toward the front of the ice maker 10. The evaporator cooling plate 90 may be heated after the formation of an ice section on the surface of the evaporator cooling plate 90 to allow for separation between the two. The temperature difference between the frozen ice section and the heated plate may produce a thin layer of water on the bottom of the ice section. The ice section may then slide off the evaporator cooling plate and down onto a cutter grid 92, where the ice section is dissected into cubes for use by consumers. The cutter grid 92 may be supported on four sides by a cutter grid frame 94. The cutter grid 92 may be engaged with an aesthetically pleasing cutter grid cover 200, shown in
(39) Another aspect of the disclosure is shown in
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(41) Turning to
(42) As illustrated, the thermistor 54 is in electrical communication with the control unit 76 to provide the control unit 76 with a signal representative of a desired level of ice, which allows the control unit 76 to start or stop the ice producing cycle. Thus, as the level of ice within the ice storage area 50 is raised, the sensed temperature of the thermistor 54 at its predetermined height decreases. Once the sensed temperature by the thermistor 54 reaches a predetermined temperature, the thermistor 54 sends a signal to the control unit 76, which is in electrical communication with the water inlet valve 78, the evaporator plate 90, and the refrigeration unit 82, to stop or start the production of ice. The thermistor 54 may be a push/pull type thermistor, adjustable in at least a low, medium or high position. If the user needs more ice for a given situation, the thermistor 54 may be selectively adjusted into a higher position within the ice storage element 52 without the use of tools. The thermistor 54 may be configured to fit into a sleeve 56 that has apertures or indentations where protrusions extending from the thermistor engage and snap into, thereby providing the user with at least a predetermined low, medium, and high settings. Additionally, the thermistor 54 may be configured with a channel type or other slidable engagement connection to allow the thermistor to slide freely within the sleeve 56. It is contemplated that a variety of slidable or adjustable type connection may be utilized that provide the themistor 54 with series of predetermined stopping points allowing an infinite number of level choices between an area approximately at the low and an area approximately at the high position. It has also been contemplated that this type of adjustable level sensing may be also used in an ice maker portion configured within a conventional refrigerator.
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(44) The filtration housing 88 may have an inlet connection fitting 84 configured to receive the water line overmold 146 associated with the water supply inlet and the filter outlet water line 138. The water supply inlet and filter outlet water line 138 are illustrated in a configuration direction substantially perpendicular to the axis of the filter housing 88. A filtration element 72 may be at least one of slidably and rotatably engaged with the filter housing 88. As illustrated the filtration element 72 is inserted into the control housing 70 and rotated into home position within the filter housing 88, thereby providing fluid communication between the water supply inlet and the filter outlet water line 138. However, the fluid path may be configured such that when the filtration element 72 is not engaged properly or present within the control housing 70, the filtration element 72 may be bypassed and the inlet connection fitting 84 and outlet connection fitting 86 may be in direct fluid communication.
(45) As illustrated, the overmolds 146 are configured to attach to the inlet connection fitting 84 and outlet connection fitting 86 at an angle substantially perpendicular to the axis of the filter housing 88. The control housing 70 may include collars 142 configured to contact the water line connectors to prevent any movement of the connectors relative to the filter housing 88. The collars 142 may prevent damage or disconnection of the water line connectors to the filter housing 88. The control housing 70 may include a filter cover 91 configured with water line guides 140, the water line guides 140 may be configured to have a radius substantially the same as the outer diameter of the water supply inlet and filter outlet water line 138, preventing kinking of the water lines from a force acting substantially perpendicular to the axis of the water lines.
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(47) The present disclosure has been particularly shown and described with reference to the foregoing illustrations, which are merely illustrative of the best modes for carrying out the disclosure. It should be understood by those skilled in the art that various alternatives to the illustrations of the disclosure described herein may be employed in practicing the disclosure without departing from the spirit and scope of the disclosure as defined in the following claims. It is intended that the following claims define the scope of the disclosure and that the method and apparatus within the scope of these claims and their equivalents be covered thereby. This description of the disclosure should be understood to include all novel and non-obvious combinations of elements described herein, and claims may be presented in this or a later application to any novel and non-obvious combination of these elements.
(48) Moreover, the foregoing illustrations are illustrative, and no single feature or element is essential to all possible combinations that may be claimed in this or a later application. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. The invention may be practiced otherwise than is specifically explained and illustrated without departing from its spirit or scope. The scope of the invention is limited solely by the following claims.
(49) With regard to the processes, systems, methods, heuristics, etc. described herein, it should be understood that, although the steps of such processes, etc. have been described as occurring according to a certain ordered sequence, such processes could be practiced with the described steps performed in an order other than the order described herein. It further should be understood that certain steps could be performed simultaneously, that other steps could be added, or that certain steps described herein could be omitted. In other words, the descriptions of processes herein are provided for the purpose of illustrating certain embodiments, and should in no way be construed so as to limit the claimed invention.
(50) Accordingly, it is to be understood that the above description is intended to be illustrative and not restrictive. Many embodiments and applications other than the examples provided would be apparent upon reading the above description. The scope of the invention should be determined, not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. It is anticipated and intended that future developments will occur in the technologies discussed herein, and that the disclosed systems and methods will be incorporated into such future embodiments. In sum, it should be understood that the invention is capable of modification and variation.
(51) All terms used in the claims are intended to be given their broadest reasonable constructions and their ordinary meanings as understood by those knowledgeable in the technologies described herein unless an explicit indication to the contrary in made herein. In particular, use of the singular articles such as a, the, said, etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary.