ICE-Making System, Which Controls ICE Hardness

The present disclosure relates generally to refrigeration appliances and, more particularly (although not necessarily exclusively), to an ice-making system for controlling ice hardness.

Refrigeration appliances, including combination refrigerator-freezer appliances and freezer-only refrigeration appliances, frequently include icemaker systems such as automatic ice makers that produce ice cubes. Automatic ice makers can include trays with ice cavities defining cavities into which water can be deposited and frozen into ice cubes. After the ice cubes are frozen, an automatic ice maker can automatically eject the ice cubes from the tray, such as into a storage bin.

According to one example of the present disclosure, an ice-making system for a household appliance can include a housing. The housing can define an ice-making chamber that can receive liquid. The ice-making system can also include an extrusion head coupled with the housing. The extrusion head can include a plurality of openings configured to receive ice. Additionally, the ice-making system can include a heating element positioned proximate and external to the extrusion head. The heating element can heat the extrusion head at a temperature that is based on a preselected ice hardness level.

According to another example of the present disclosure, a household appliance can include an ice storage compartment and an ice-making system. The ice-making system can include a housing, which can define an ice-making chamber that can receive liquid. The ice-making system can also include an extrusion head coupled with the housing. The extrusion head can include a plurality of openings configured to receive ice. Additionally, the ice-making system can include a heating element configured to prevent a system failure associated with the ice-making system and heat the housing at a temperature that is based on a preselected ice hardness level.

According to a further example of the present disclosure, a method for producing ice pellets based on a preselected ice hardness level can include receiving, at a housing defining an ice-making chamber, liquid. The method can further include producing ice from the liquid in the housing using a heat exchange system associated with the housing. Additionally, the method can include heating an extrusion head coupled with the housing using a heating element positioned proximate and external to the extrusion head. A temperature to which the extrusion head may be heated by the heating element can be based on the preselected ice hardness level. The method may also include receiving the ice at a plurality of openings of the extrusion head. The ice may be moved to the plurality of openings by an auger positioned in the housing. Moreover, the method can include forming the ice pellets by movement of the ice through the plurality of openings of the heated extrusion head.

Certain aspects and examples of the present disclosure relate an ice-making system for controlling ice hardness. The ice-making system can be positioned in a refrigeration appliance, which may be an ice-making refrigeration appliance having an automatic ice maker. Some aspects relate to an ice-making system that includes a heating element. The heating element can be positioned around a circumference or within an extrusion head of the ice-making system. The heating element can heat the extrusion head. Adjusting a temperature of the heating element can affect a hardness of ice formed through openings in the extrusion head.

The ice-making system can further include an adjustable ice breaker for cutting ice formed through the openings in the extrusion head into ice pellets. For example, the ice breaker may be coupled with a screw thread protruding from the extrusion head. A height of the ice breaker with respect to the extrusion head can be adjusted by rotating the ice breaker to move it along the screw thread. As a result, a length of ice pellets produced by the ice-making system can be controlled. By controlling ice hardness and length, ice pellets can be produced based on user preferences. For example, small, chewable (e.g., soft) ice, large, chewable ice, or non-chewable (e.g., hard) ice can be produced by the ice-making system.

Some users may prefer ice that is significantly softer than a standard ice cube. It may be difficult to control ice hardness such that a single ice-making system can produce ice of varying hardness according to user preferences. In particular, the low temperatures of freezer compartments in refrigeration appliances can prevent production of chewable ice. Additionally, components of the ice-making systems may freeze and compress ice in a consistent manner, thereby preventing variability in ice hardness and size. To produce ice of varying size or hardness, the components of ice making systems may be interchangeable. But, interchangeable components can be difficult to use and there can be an increased risk of damage to the components during removal or placement. Additionally, to create the interchangeable components, additional manufacturing steps may be used and a complexity of manufacturing each component can be increased.

Embodiments of the present disclosure can solve one or more of the abovementioned problems via an ice-making system for controlling ice hardness. For example, the ice-making system can include a heating element positioned external and adjacent to an extrusion head. The heating element can heat the extrusion head, which can increase a temperature at which the ice is formed as it is pushed through and compressed at openings of the extrusion head. When the extrusion head is at a higher temperature, the ice-making system can produce softer ice than when the extrusion head is not heated or is kept at a lower temperature. Additionally, a motor can cause an auger within the ice-making system to rotate. An increase in auger rotation speed (e.g., auger rotations per minute (RPM)) can increase a hardness of ice produced by the ice-making system. A water fill system can also provide a particular water volume to the ice-making system. By increasing a volume of water in the ice-making system, ice hardness can be increased. A temperature of the ice-making system can also affect ice hardness. For example, maintaining the ice-making system at a higher temperature can result in the ice-making system producing softer ice. By adjusting extrusion head temperature, water volume, ice-making system temperature, and auger speed, an ice-making system can be provided that can produce ice of varying hardness without additional or interchangeable components.

Further, a motor and gear box assembly can be positioned next to or above a top side of the ice-making system, which can be outside of an area in which moisture from the ice-making system may leak (e.g., below an ice-making chamber). This positioning can decrease a risk of damage to the motor and gear box assembly, which in turn can increase an operational life of a motor or other components within the motor and gear box assembly.

Although pieces of ice produced by an ice-making system according to various aspects are referred to as “ice pellets” or “ice cubes,” this can refer to other shapes of ice beyond pellet or cuboid shapes. For example, ice pellets may be produced in cylindrical shapes, accordion shapes, button shapes, conical shapes, round dimple shapes, donut shapes, square shapes, pyramid shapes, bar shapes, or any other suitable shape.

Illustrative examples are given to introduce the reader to the general subject matter discussed herein and are not intended to limit the scope of the disclosed concepts. The following sections describe various additional features and examples with reference to the drawings in which like numerals indicate like elements, and directional descriptions are used to describe the illustrative aspects, but, like the illustrative aspects, should not be used to limit the present disclosure.

depicts a household appliancethat can include an ice-making system according to some examples of the present disclosure. The household appliancecan be a freezer, a refrigerator, or a combination thereof. For example, the household appliancecan include a first compartmentdefining a refrigeration space and a second compartmentdefining a freezer space. The first compartmentand the second compartmentmay be arranged in various orientations, such as the first compartmentpositioned above the second compartmentas depicted in. In another example, the first compartmentmay be positioned side by side or below the second compartment, or in any other suitable arrangement. The first compartmentor the second compartmentmay include an ice-making system. Additionally, the household appliance can include an ice dispensing system, which may receive ice from the ice-making system and dispense the ice from the household appliance. For example, as depicted in, an ice dispensing systemcan be integrated within a doorof the household appliance.

depicts another example of the household appliancethat can include the ice-making systemaccording to some examples of the present disclosure. As shown, the ice-making systemcan be positioned in the first compartment. In other examples, the ice-making systemcan be positioned elsewhere in the first compartmentor in the second compartment. The household appliancecan include shelves-and drawers-, which may be used for storing items (e.g., food and beverages) in the household appliance.

depicts a cross-sectional view of the household appliancethat can include the ice-making systemaccording to some examples of the present disclosure. The ice-making systemcan include at least a first housing, a motor and gear box assembly, and a tank. The motor and gear box assemblycan be positioned on a side or above the first housingto minimize contact of the motor and gear box assemblywith excess liquid (e.g., water) from the first housing. In this way, a likelihood of damage to a motoror other components of the motor and gear box assemblycan be minimized, enabling the motoror other components to work more effectively and for a greater length of time.

The first housingcan include additional components of the ice-making systemsuch as a second housing defining an ice-making chamber, an extrusion head (e.g., extrusion headdepicted in), and an auger (e.g., augerdepicted in). The additional components are described below with respect to. Additionally, as illustrated, a backside of the doorcan include an ice chute. The ice chutecan be part of the ice dispensing systemdepicted in. The ice chutecan be an opening defined in the doorthat can receive the ice produced by the ice-making system. The ice chutemay lead to an opening in a front side of the doorthrough which ice can be dispensed from the household appliance.

depicts an example of the ice-making systemfor controlling ice hardness according to some examples of the present disclosure. The ice-making systemcan include at least a motor and gear box assemblyand a tank. The ice-making systemcan also include a storage compartment. Ice pellets produced by components of the ice-making system(e.g., by an auger, extrusion head, and ice breaker) can be stored in the storage compartment. The storage compartmentcan have a temperature around −3 or −2 degrees Celsius. The temperature of the storage compartmentmay be different from a temperature of a compartment (e.g., the first compartment) of the household appliancein which the ice-making systemis positioned. For example, if the compartment of the household applianceis a freezer compartment, the temperature of the storage compartmentcan be greater than the temperature of the freezer compartment. In contrast, if the compartment of the household applianceis a refrigeration compartment, the temperature of the storage compartmentcan be less than the temperature of the refrigeration compartment.

depicts a side view of an example of the ice-making systemfor controlling ice hardness according to some examples of the present disclosure. The ice-making systemcan correspond to the ice-making systemdepicted in. The ice-making systemcan include a first housingin which at least some of the components of the ice-making systemcan be positioned. For example, the first housingcan include a second housing defining an ice-making chamber. Additionally, in some examples, an ice breaker, an extrusion head, an auger, a cooling tube, or a combination thereof can be at least partially positioned within the first housing.

A motor and gear box assemblycan be connected to one or more components within the first housing. For example, a motor(e.g., a shaded pole motor or other suitable type of motor) of the motor and gear box assemblycan traverse the extrusion headand be coupled with the auger. As a result of being coupled with the auger, the motorcan cause the auger to rotate. Rotation of the auger within the first housingcan generate ice shavings and can move the ice shavings towards and through openings in the extrusion head. As the ice shavings are pushed through the openings, the ice shavings can be compacted to produce ice cubes. The ice cubes can then be broken into pieces of ice (e.g., ice pellets) by the ice breaker. In some examples, a sweeping mechanismcan be coupled with the ice breaker and rotate about the ice breaker. In doing so, the sweeping mechanismcan push the pieces of ice into a storage compartment (e.g., storage compartment) associated with the ice-making system.

The ice-making systemcan further include a liquid fill assembly, which can control a volume of liquid (e.g., water) entering the tank. The tankcan also be part of the ice-making systemand can store liquid to be used in ice production. The tankcan include a slot under a removable capand an outlet. The slot can provide an opening for inserting a descaling tablet or other suitable cleaning means into the tank. Additionally, to transport liquid from the tankto the first housing, an inlet linecan be connected to the outletof the tankto an inletof the first housing.

The ice-making systemcan also include one or more (e.g., two) heat exchange systems in series, which can include at least the cooling tubeand an evaporator. The cooling tubecan work to freeze liquid in the ice-making system. For example, the cooling tubecan carry refrigerant to the first housing. As illustrated, the first housingcan include an inlet through which the cooling tubecan enter. Simultaneously, the cooling tubecan carry refrigerant to the evaporator. As a result of refrigerant passing through the cooling tubewhich is in contact with the evaporator, the temperature of the first housingand a storage compartment (e.g., storage compartment) can be below freezing.

depicts a perspective view of an ice-making systemfor controlling ice hardness according to some examples of the present disclosure. The ice-making systemcan correspond to the ice-making systemdepicted in. The ice-making systemcan include a first housingin which at least some of the components of the ice-making systemcan be positioned. For example, a second housing defining an ice-making chamber, an auger, and cooling tubecan be at least partially positioned within the first housing.

The ice-making systemcan include a motor and gear box assembly, which can include a motor, a gear box, and a rod. The rodcan traverse an extrusion headand can be coupled with an auger within the first housing. The motorcan rotate, and the rotation of the motorcan be translated to the rodvia one or more gears within the gear box. Due to the coupling of the rodand auger, the rotation of the rodcan cause rotation of the auger. Rotation of the auger within the first housingcan generate ice shavings and can move the ice shavings towards and through openings in an extrusion head. As the ice shavings are pushed through the openings, the ice shavings can be compacted to produce ice cubes. The ice cubes can then be broken into pieces of ice (e.g., ice pellets) by an ice breaker.

Additionally, a tankcan be connected to the second housing defining the ice-making chamber within the first housing. For example, an outletof the tankcan be coupled with an inlet line. The inlet linecan further be coupled with a first inletof the first housingand an inlet of the second housing. Examples of the second housing defining the ice-making chamber are shown and described below with respect to. Liquid can be provided to the first housing defining the ice-making chamber from the tankvia the inlet line. The tankcan further include a slot with a removable cap. Upon removal of the cap, the slot can provide an opening for inserting a descaling tablet or other suitable cleaning means into the tank.

The ice-making systemcan also include a heat exchange system with at least one cooling tubeand evaporator. The at least one cooling tubeand evaporatorcan work together to freeze water in the ice-making chamber and cool the storage compartment. For example, the cooling tubecan carry refrigerant to the ice-making chamber within the first housing. As illustrated, the first housingcan include one or more inlets (e.g., a second inletand a third inlet) through which the cooling tube can enter and come in contact with the ice-making chamber. The cooling of the refrigerant in the cooling tubealso facilitates the evaporatorcooling the ice storage compartment. As a result of cooling the refrigerant passing through the tubes, the temperature of the ice-making systemcan be below freezing.

depicts a cross-sectional view of an ice-making systemfor controlling ice hardness according to some examples of the present disclosure. The ice-making systemcan correspond to any of the ice-making systems shown and described above with respect to. The ice-making systemcan include a first housingin which at least some of the components of the ice-making systemcan be positioned. For example, a second housingdefining an ice-making chamber, an auger, a thermistor, a cooling tube, and one or more heaters-can be positioned within the first housing.

The cooling tubecan be coiled around the second housingto create a cold environment within the second housing. As a result, liquid (e.g., water) in the first housing, which can be received via an inlet line (e.g., inlet linedepicted in), can freeze. The thermistorcan be used to measure and monitor a temperature of the second housing. The augercan rotate within the second housing. As illustrated, the augercan be a helical screw blade. The rotation of the augercan break or scrape the frozen water in the second housingto create ice shavings. The rotation of the augercan further push the ice shavings upward to an extrusion head. In some examples, in contrast to the cooling tube, the heaters-can heat the second housingto increase an ease at which the ice can be scraped or broken by the auger. In particular, the heaters-can improve an ease at which the augercan scrape ice from an inner wall of the second housing. The heaters-can further prevent a system failure at the ice-making systemby preventing the ice-making system from freezing up.

The extrusion headcan include openings-through which the ice shavings can be pushed. The ice shavings can be pushed through the openings-due to the continuous generation of ice shavings and upward movement of the ice shavings facilitated by the augerrotation. In being pushed through the openings-, the ice shavings can be compressed into ice cubes with a shape corresponding to a shape of the openings-. For example, if the openings-are circular, the ice cubes can be cylindrical.

Additionally, a heating elementcan be positioned around a circumference of the extrusion head. The heating elementcan heat the extrusion head, which can affect a hardness of the ice formed as it is pushed through the openings-. For example, an increased temperature of the extrusion headcaused by the heating elementcan result in softer ice. The extrusion headcan further include a protrusion. The protrusioncan include a screw thread on which the ice breakercan be coupled. The ice breakercan break the compacted ice pushed through the openings-to produce pieces of ice (e.g., ice pellets) of a particular length.

After ice pellets are formed (e.g., broken by the ice breaker), an ice guidecan guide the ice pellets into a storage compartment, such as storage compartmentdepicted in. Additionally, any excess water from the second housingcan be guided away from the storage compartment by a liquid guide. By guiding the excess water away from the compartment, ice pellets within the compartment can be less likely to stick together. Additionally, a risk of damage to the compartment, which can be caused by the excess water, can be reduced.

Additionally, to produce ice of varying hardness, various parameters associated with the ice-making systemcan be controlled. The parameters which can affect ice hardness can include a temperature of the second housing, rotations per minute (RPM) of the auger, a temperature of the heating elementassociated with the extrusion head, and a water volume within the second housing.

For example, a higher volume of liquid within the second housingcan result in the ice-making systemproducing ice with greater hardness than a lower volume of water. Additionally, retaining the first housing, the second housing, or the heating elementat a colder temperature can be associated with the ice-making systemproducing ice with greater hardness than warmer temperatures. A higher RPM of the augercan also cause an increase in ice hardness with respect to a lower RPM. Thus, by adjusting housing temperature, heating element temperature, auger RPM, volume of liquid within the second housing, or a combination thereof the ice-making systemcan produce ice of varying hardness.

In some examples, the ice-making systemcan include a controller, which can receive a user selection of an ice hardness level. For example, a user interface of the household appliancemay include ice hardness level options (e.g., a first ice hardness level, a second ice hardness level, and a third ice hardness level). Then, based on the preselected ice hardness level, the controller can transmit a signal to a liquid fill assembly (e.g., liquid fill assemblydepicted in) to cause the liquid fill assembly to provide a particular amount of water to a tank, and therefore to the second housingwithin the first housing. For example, the controller can cause the liquid fill assembly to provide a volume of water that is between fifty and one hundred percent of a total volume of an inside of the second housing. Additionally or alternatively, the controller can transmit a signal to the heat exchange system causing the heat exchange system to change a temperature of the ice-making system. For example, the temperature of the ice-making systemor of the first housingor the second housingin particular may be between negative ten and negative one degree Celsius. Additionally, in some examples, the controller can transmit a signal to the motor to change an RPM of the auger. For example, the auger RPM can be between five and nine. Additionally, as described above, a heating elementcan be associated with the extrusion head. The controller can further transmit a signal to the heating element to control a temperature of the heating element and thereof of the extrusion head.

As a result of the controller transmitting one or more signals to the motor, the heat exchange system, the heating element, the liquid fill assembly, or a combination thereof, the ice-making systemcan produce ice with a hardness corresponding to the preselected ice hardness level. The hardness can be a measure of a maximum force at which the ice breaks and can be expressed in Newtons (N). In some examples, a first ice hardness associated with the first ice hardness level can be below 30 N, a second ice hardness associated with the second hardness level can be between 30 N and 50 N, and a third ice hardness associated with the third hardness level can be greater than 50 N.

depicts a perspective view of an extrusion headfor an ice-making system according to some examples of the present disclosure. The extrusion headcan correspond to the extrusion headdepicted in, the extrusion headdepicted in, the extrusion headdepicted in, or a combination thereof. In an ice-making system (e.g., the ice-making systems depicted in), ice shavings can be pushed out of a housing defining an ice-making chamber via openings-of the extrusion head. In doing so, the ice shavings can be compressed into ice pellets of a desired form. The extrusion headcan further include a protrusionwith a screw thread. An ice breaker can be coupled with the extrusion headvia the screw thread. Additionally, a heating elementcan be positioned external and proximate to the extrusion head. The heating elementcan correspond to the heating elementdepicted in. The heating elementcan heat the extrusion head, which can affect a hardness of the ice formed as it is pushed through the openings-

depicts a perspective view of a tankfor an ice-making system according to some examples of the present disclosure. The tankcan correspond to the tankdepicted in, the tankdepicted in, the tankdepicted in, or a combination thereof. The tankcan include a slotthrough which a descaling tablet can be inserted into the tank. In some examples, the slotcan be covered by a removable cap such as capdepicted in. Additionally,depicts a cross-sectional view of the tankfor an ice-making system according to some examples of the present disclosure. The tankcan include a float switchfor measuring a volume of liquid within the tank. The tankcan further include a heaterfor controlling a temperature of the tankand a thermistorfor measuring and monitoring the temperature of the tank.

depicts a perspective view of a housingdefining an ice-making chamber for an ice-making system according to some examples of the present disclosure. The housingcan correspond to the second housingdepicted in. As illustrated, a cooling tubecan be coiled around the housingto create a cool environment to freeze liquid in the housing. The cooling tubecan correspond to the cooling tubeof, the cooling tubeof, the cooling tubeof, or a combination thereof.

depicts a perspective view of an augerfor an ice-making system according to some examples of the present disclosure. The augercan be positioned in a center of the second housingof. The augercan be a helical screw blade that can rotate to break and shave ice formed within an ice-making chamber. The rotation of the augercan further push ice shavings in an upward direction to facilitate production and ejection of ice pellets from an ice-making system.

depicts a flow chart of a processfor producing ice pellets based on a preselected ice hardness level according to some examples of the present disclosure. The processcan be performed by an ice-making system, such as the ice-making systemdepicted in, the ice-making systemdepicted in, the ice-making systemdepicted in, or the ice-making systemdepicted in. In other examples, the processcan include more steps, fewer steps, different steps, or a different order of the steps depicted in. The steps ofare described below with reference to components discussed above in.

At blockthe processcan involve receiving, at a housingdefining an ice-making chamber, liquid. The liquid can be water or another suitable liquid. The liquid can be transferred to the housingvia an inlet line, which can connect to an outlet of a tank and an inlet of the housing. A volume of water transferred to the housingmay be controlled by a liquid fill assembly. For example, based on a preselected ice hardness level, a controller may transmit a signal to the liquid fill assembly to cause the liquid fill assembly to provide a particular volume of liquid to the tank. In a particular example, the particular ice hardness level can be a lowest or softest ice hardness level. For example, a hardness corresponding to the preselected ice hardness level can be around 20 N. In the particular example, the signal may cause the liquid fill assembly to provide a volume of liquid equal to 50% of a total volume of the housingto the tank. As a result and due to the connection of the tank and housingvia the inlet line, the housingcan receive the volume of liquid.

At blockthe processcan involve producing ice from the liquid in the housingusing a heat exchange system associated with the housing. The heat exchange system, which can include one or more cooling tubesand an evaporator. A portion of the cooling tubecan run through the evaporator and another portion of the cooling tube can be in contact with the housing. The evaporator can facilitate cooling of the refrigerant in the cool tube. As a result, of cooling the refrigerant, the temperature of the housingcan be controlled. In some examples, based on the preselected ice hardness level, the controller can transmit a signal to the heat exchange system to control the temperature of the housing. In the particular example, the temperature of the housingfor the preselected ice hardness level can be around negative ten degrees Celsius.

At blockthe processcan involve heating an extrusion headcoupled with the housingusing a heating elementpositioned proximate and external to the extrusion head. A temperature to which the extrusion headis heated by the heating elementcan be based on the preselected ice hardness level. In some examples, based on the preselected ice hardness level, the controller can transmit a signal to the heating elementto control a temperature of heating elementand therefore the heating of the extrusion head. In some examples, the heating elementmay have a cold setting associated with a low temperature (e.g., between 0 to 10 degrees Celsius) and a hot setting associated with a high temperature (e.g., a temperature greater than 10 degrees Celsius). In the particular example, the signal can cause the heating element to be on the hot setting.

At block, the processcan involve receiving the ice at a plurality of openings-of the extrusion head. The ice can be moved to the plurality of openings-by an augerpositioned in the housing. In some examples, the augercan be rotated using a component (e.g., a motor or rod) of a motor and gear box assembly. The component of the motor and gear box assembly can traverse the extrusion headand can be coupled with the auger. In some examples, the controller can transmit a signal to a motor of the motor and gear box assembly to control a rotations per minute (RPM) of the augerbased on the preselected ice hardness level. In the particular example, the signal can cause the auger to rotate at 5.4 RPM.

At block, the processcan involve forming the ice pellets by movement of the ice through the plurality of openings-of the extrusion head. Additionally, forming the ice cubes can include cutting the ice as it comes outward from the openings-using an ice breakercoupled with a protrusionof the extrusion head. The ice breakercan be rotated about the protrusionto adjust a position of the ice breakerrelative to a surface of the extrusion head. For example, for small ice, the ice breakercan be rotated downward such that a position of the ice breakeron the protrusion is closer to a top surface of the extrusion head.

The foregoing description of certain examples, including illustrated examples, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art without departing from the scope of the disclosure.