Note: Descriptions are shown in the official language in which they were submitted.
CA 02545021 2006-04-27
TITLE: REFRIGERATOR WITH IMPROVED WATER AND ICE DISPENSER
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to Canadian Patent Application 2,531,469 filed
December 22, 2005, entitled REFRIGERATOR WITI-I FORWARD PROJECTING
DISPENSER.
BACKGROUND OF THE INVENTION
The present invention relates generally to refrigerators and more particularly
to ice
and water dispensers located on the outer surfaces of the doors of
refrigerators. As is well
known, a refrigerator may be provided with an ice dispenser and a water
dispenser. Such
dispensers typically are mounted in a front panel of a refrigerator door. In a
side-by-side
refrigerator, the dispenser generally is located in the freezer compartment
door. Each
dispenser typically has a lever, actuator button, or actuator pad disposed at
the rear most
surface of the housing into which a glass or cup can be inserted for filling.
A glass may be
pressed against the actuation button, pad, or lever, thus activating the
dispensing of water
or ice cubes, as desired.
Typically, the dispenser has a cavity that is inset into a door of the
refrigerator. The
inset cavity of the dispenser takes up valuable storage space within the inner
compartment.
This storage space is further compromised when an actuator and other circuitry
is located at
the rear side of the dispenser cavity.
Additionally, dispensers located within a door compartment have a cavity which
receives only limited size beverage containers. For example, a typical water
and ice
dispenser can receive a beverage glass that holds 12 - 16 ounces of fluids but
not a
thermos, cooler, or large capacity beverage glass such as a 48-ounce or 64-
ounce cup.
Dispensers typically have another problem with showering the user with ice
chips
and water spray when the dispenser is being used. This is mostly due to the
fact that an ice
chute and water tube are located out of sight up above the control panel for
the dispenser
and therefore a user cannot see exactly where to locate the container which is
to be filled.
Then, ice chips or water spray splatters about. Thus, it is desirable to have
a dispenser
CA 02545021 2006-04-27
which reduces splattering ice chips and water and helps the user to determine
proper
location of the container for dispensing.
Another problem with typical dispensers is that the ice chute door is
typically
opened and closed with an electrical solenoid. The solenoid is usually
relatively noisy,
creating an electric buzz or snap sound as the solenoid actuates, causing the
dispenser door
to open or close. Additionally, solenoids have a relatively high power
consumption.
Therefore, it is desirable to have an ice chute door which is operable with
less power
consumption, and less noise.
A further problem with typical dispensers is that they leak air between the
ice box
and the ice chute. This is mostly because of manufacturing variances in parts.
This in turn
causes cold air loss, and moisture/ice buildup. Therefore, it is desirable to
reduce air leak
between the ice chute and the ice box.
Thus, a primary objective of the present invention is the provision of an
improved
water and ice dispenser for a refrigerator.
Accordingly, one feature or advantage of the present invention is the
provision of
an ice and water dispenser that allows for increased storage capacity behind
the ice and
water dispenser.
Another feature or advantage of the present invention is the provision of an
ice and
water dispenser that accommodates large cups, water bottles, pitchers,
thermoses, coolers,
etc.
Another feature or advantage of the present invention is the provision of an
ice and
water dispenser which helps a user to locate the receiving container in the
proper location
and also helps to reduce splatter or spray of ice chips or water on the user.
Another feature or advantage of the present invention is the provision of an
ice and
water dispenser that has a lower power consumption and a quieter ice chute
door.
Another feature or advantage of the current invention is reduced air leak
between
the ice chute and the ice box.
One or more of these or other features or advantages will become apparent from
the
following specification and claims.
2
CA 02545021 2006-04-27
SUMMARY OF THE INVENTION
The present invention is directed towards a refrigerator with a forward
projecting
ice and water dispenser attached to the front panel of a refrigerator door. In
general, the
door of the invention includes an outer door pan, an inner door liner, an ice
chute extending
5 through the door, and a dispenser engaging the ice chute. The
refrigerator~door of the
present invention has an outer door cavity and an inner liner cavity.
One feature of the present invention is an ice chute that is in both the liner
cavity
and the outer door cavity. This positioning of the ice chute permits the
dispenser to be
placed forward the front panel of the door to receive ice from the ice chute.
10 A further feature of the present invention is a more efficient utilization
of storage
space upon the inner liner. The forward projecting dispenser makes unnecessary
a deep
dispenser cavity in both the outer door and the inner liner which necessitates
a deep inner
liner cavity to accommodate the dispenser protruding into the door.
A further feature of the invention is the ability to permit oversized cups,
water
15 bottles, pitchers, coolers, thermoses, etc. being filled more easily as
they do not need to fit
within a cavity protruding into the refrigerator door. One problem typically
encountered
with filling oversized containers is a drip tray interfering with the
positioning of the
oversized container underneath the ice and/or water dispenser. Therefore, a
feature of the
present invention is a retractable drip pan adjacent the front panel of the
refrigerator door
20 or removable from the front panel. Additionally, the drip tray may be
independent the
dispenser and attached by a magnet or other attachment means which may be
moved when
oversize containers are being filled.
A further feature of the invention is a dispenser with a retracting ledge
moveable
between a first position and a second position which can be used for holding
or supporting
25 containers in shallow dispensers. The retracting ledge can then be moved
out of the way
when not needed.
A further feature of the present invention is a dispenser with an angled back
side.
Having an angled back side, allows more storage space inside the refrigerator
compartment
along the door.
30 A further feature of the present invention is a lighted dispenser target
ring extending
at least partially around the water tube and the ice chute. The lighted
dispenser target ring
CA 02545021 2006-04-27
allows a user a target area for locating the receiving container during
dispensing and
additionally helps to block oversprayed water or ice chips.
A further feature of the present invention is an ice and water dispenser with
an ice
chute door openablc with an electric motor. The electric motor rotates a cam
which in turn
flips open the ice chute door. This allows for quieter opening of the ice
chute door and less
power consumption during opening of the ice chute door over standard solenoid
operated
ice chute doors.
A further feature of the invention is an ice chute air seal between the ice
chute and
the ice box. This reduces cold air loss from the ice box and therefore reduces
moisture/ice
buildup.
Additional objects, features and advantages of the present invention will
become
more readily apparent from the following detailed description of the preferred
embodiments when taken in conjunction with the drawings wherein like reference
numerals refer to corresponding parts in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a front elevation view of a refrigerator having a forward
projecting
dispenser with a drip pan included with the dispenser housing.
Figure 2 is a side elevation view of the freezer door of Figure 1.
Figure 3 is a rear elevation view of a door using a forward projecting
dispenser.
Figure 4 is a cross sectional view taken along line 4-4 of Figure 1.
Figure 5 is a front view of a door with a forward projecting dispenser of the
present
invention with a drip pan independent and removable from the dispenser
housing.
Figure 6 is a front view of the door of Figure 5 with the drip pan removed.
Figure 7 is a front view of a door with a forward projecting dispenser without
a
dispenser cavity.
Figure 8 is a side view of the door of Figure 7.
Figure 9 is a cross sectional view taken along line 9-9 of Figure 7.
Figure 10 is a sectional side view of another embodiment of a dispenser in a
refrigerator door.
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CA 02545021 2006-04-27
Figure I 1 is a perspective view looking upwardly from a front side of a
dispenser
up into the dispensing cavity and the ice chute.
Figure 12 is one embodiment of an ice chute actuator assembly.
Figure 13 is an ehploded view of the actuator assembly of Figure 12.
Figure 14 is a perspective view of an inside of a refrigerator door showing an
ice
chute air seal.
Figure 14A is a side view of a refrigerator showing the ice chute air seal.
Figure 15 is a front view of a prior art ice and water dispenser.
Figure 16 is a side view of the prior art ice and water dispenser of Figure
15.
Figure 17 is a cross sectional view taken along line 17-17 of Figure 15.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will be described as it applies to its preferred
embodiment. It
is not intended that the present invention be limited to the preferred
embodiment. It is
1 S intended that the invention cover all modifications and alternatives that
may be included
within the spirit and scope of the invention.
With reference to Figure 1, a conventional refrigerator 10 is shown,
refrigerator 10
being of the side-by-side design, wherein refrigerator 10 has a refrigeration
compartment
sealed by a refrigerator door 12 and a freezer compartment sealed by a freezer
door 14.
One of the doors 12, 14 may be provided with a dispenser 16, generally
including a
housing 18 defining a dispensing area 22 for an ice chute 20 and water tube
34.
Dispenser 16 may utilize ice and/or water selection buttons 28 and an actuator
29.
The user may select water and/or the type of ice to be dispensed such as ice
cubes or
crushed ice using buttons 28. The user selects and dispenses ice and water by
pressing
actuator button 29 that actuates delivery of ice through the ice chute 20
and/or water
through the water tube 34.
It should be noted that the dispenser 16 could also be found in other types of
refrigerators, other than those of side-by-side construction, and thus the
dispenser of the
present invention, as will hereinafter be described in greater detail, can
similarly be used in
both refrigerators of side-by-side design, as well as other designs.
CA 02545021 2006-04-27
'fhe refrigerator 10 has handles 26 extending outward. The dispenser 16
extends
outward from the door 14. As shown in Figure 2 the dispenser may extend
approximately
level with the handles 26. Alternatively, the dispenser may extend beyond the
handle
especially when no dispensing cavity 22 is provided for and as illustrated in
Figure 8.
Figure 2 illustrates the side of the ice and water dispenser 16. Dispenser
housing 18
frames the control panel 24, the dispensing area 22, and a catch tray or drip
pan 32. The
control panel 24 and drip pan 32 extend forward the front panel 46 of the
outer door panel.
As seen in Figure 2 and Figure 3, the forward projecting dispenser 16 permits
the
ice chute 20 to be the only structure within an inner liner cavity 44. In
contrast, the prior
art as seen in Figures 10-12 require an inner liner cavity 44A to not only
accommodate an
ice chute but also the dispenser cavity. Accordingly, the forward projecting
dispenser
permits a space 40 to be available for a shelf 42. This extra space 40 is an 1
I-inch to 12-
inch area below the ice chute 20.
In general, the doors, 12, 14 include an outer door pan 30 and an inner liner
38.
The outer door pan 30 is formed of sheet metal and includes a front panel
portion 46. The
door pan 30 can also be constructed of plastic or a combination of metal and
plastic. The
sheet metal is bent so as to form a top, bottom and opposing side wall
portions 48.
Typically, the piece of sheet metal is further bent to define a plurality of
flange portions
(not shown). The inner door liner 38 is thermal formed but could also be
injection molded.
In any event, inner door liner 38 includes a portion which defines the inner
liner cavity.
The inner liner 38 attaches to the outer door pan 30 typically at the
plurality of flange
portions. Insulation foam is then filled into the void defined by the outer
door cavity 50
and the inner liner cavity 44.
As seen in Figure 4, the ice chute 20 extends through both the liner cavity 44
and
the outer door cavity 50. Storage space is maximized by having the liner
cavity 44 partially
defined by an angled side 36 that follows the diagonally mounted ice chute 20.
This is
different than the prior art as seen in Figure 12 which only has the ice chute
20 extending
through the liner cavity 44.
As further seen in Figure 4, the forward projecting dispenser 16 permits a
less deep
ice dispenser cavity 22. As seen in Figures 4, 9, and 10 the dispenser cavity
22 may have
an angled back side or sloped dispensing cavity 23 protruding into the outer
door cavity
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CA 02545021 2006-04-27
portion of the outer door pan 30. A drip pan 32 may be placed on the front
panel 46 by an
attachment such as screws or may be magnetically attached so that it may be
removed as
seen in Figures 5 and 6. The drip pan 32 may be removed whenever larger
containers or
oversized containers are desired to be filled.
5 Figure 10 shows an embodiment of an ice and water dispenser 16 with an
angled
backside or sloped dispensing cavity 23. The sloped dispensing cavity 23 is
preferably
projected no more than one inch from the door pan 30. While other depth of
projections
are also within the scope of the invention, deeper projections reduce storage
space inside
the refrigerator door. The back slope of the cavity 23 is angled upward and
inward with
10 respect to an inside of the refrigerator to minimize the space required by
the dispensing
cavity 22. This configuration maximizes space available inside of the fresh
food or freezer
compartment. Thus, the shallow dispensing cavity 23 allows for extra space 40
and
therefore an extra shelf or storage bin 42 in the door.
As seen in Figures 7-9, an alternate embodiment of the forward projecting
dispenser
15 16 does not utilize a dispensing cavity 22. The dispenser 16 extends
forward from the front
panel 46 a distance beyond the handle 26 to accommodate large and oversized
containers.
Additionally, a depressible actuator 29A is provided that is pushed inwardly
to actuate the
dispensing of ice and/or water. The actuator 29A doubles as a drip pan 32 and
catches
excess water when it is released for return back into place under the water
tube 34. The
20 actuator 29A is removable for cleaning.
The prior art, as seen in Figures 15-17, only shows the ice chute 20 in the
inner
liner 38 portion and specifically a liner cavity 44. The liner cavity is
elongated to insulate
the dispenser cavity 22B. The actuator 29B and related circuitry is at the
rear of the cavity
22B. Also the drip pan 32B is within the cavity 22B. As seen most clearly in
Figure 16,
25 the dispenser 16B is approximately flush with front panel 46 as opposed to
forward
projecting.
The dispenser 16 includes a retractable ledge 33, as best seen in Figure 10.
The
ledge 33 is movable between an extended position shown in Figure 10 wherein
the front
edge is positioned outwardly from the front surface of the door 12 and a
retracted position
30 in Figure 11 wherein the front edge is flush with the front surface of the
door 12. The
ledge 33 is configured as a tray drip pan 32 but does not have to be. The
retracting ledge
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CA 02545021 2006-04-27
3 3 can be temporarily extended from the shallow main dispenser area 22 to
accommodate
setting a glass, a pitcher, or other container during ice or water dispensing.
The retracting ledge _i3 can be designed to pull out, fold up, fold down, or
even be
removable. As seen in Figure 10, the retracting ledge 33 slides in a groove
31. It is
preferred that the retracting ledge 33 have a stop (not shown) which prevents
the retracting
ledge 33 from being easily removed iiom the dispensing cavity 22. The groove
31
additionally helps support the retracting ledge 33 when the ledge 33 is
supporting a glass,
pitcher, or other container during dispensing. The ledge 33 is most useful in
dispensers
having a shallow dispensing area 22, however, the ledge 33 can also be used in
a dispenser
16 having a deeper dispensing area 22.
As best seen in Figures 10 and 1 l, the dispenser 16 has a lighted dispenser
target
60. The lighted dispenser target 60 is preferably a light pipe which gathers
light from the
cavity light, such as light emitting diodes 62, to provide a lighted ring, or
similar device, as
a target for a glass in the dispenser cavity 22. A portion of the light
provided to the cavity
15 22 is captured by a portion of the lighted dispenser target 60 which
directs the light around
the opening for ice and water into the cavity 22. The lighted dispenser target
60 also helps
to contain ice chips and spray from the user of the dispenser 16. Since the
lighted
dispenser target 60 is capturing light from the dispenser light source 62, it
is preferred to be
of a transparent or at least translucent material. The shape of the lighted
target dispenser
20 60 is shown as a rounded arc. This shape works best for containing water
spray and ice
chips, however, any shape can be used. As best seen in Figure 11, the lighted
dispenser
extends downwardly around or in front of target 60 and the water tube 34 and
ice chute 20
so as to protect a user from water or ice spray.
Prior art dispensers have used lighted actuator arms which provide a target
for
25 placement of a glass during use of the dispenser 16. However, a lighted
actuator arm does
nothing to help reduce water spray or ice chip splatter.
As best seen in Figures 12 and 13, the dispenser 16 has a motorized ice chute
door
assembly 70. Figure 12 is a perspective view from the back and side of the
assembly 70.
Figure 13 is an exploded view from the top/front/side of the assembly 70. A
low current
30 draw motor 82 is used to move the ice chute door 21. The ice chute door 21
substantially
closes off the ice chute 20 when not dispensing ice so as to reduce cold air
loss from the ice
CA 02545021 2006-04-27
making or storage compartment. The motor 82 opens the ice chute door 21 a
sin<~ a cam 88.
A position switch 92 is provided to re~~ister the ice chute door 21 position
as "open" or
"closed". An ice chute door hinge 7=1 and spring 76 biases the ice chute door
21 to a closed
position with respect to the ice chute 20. The motorized ice chute door
assembly 70
replaces the commonly used solenoid-opened-ice chute door. -
In the preferred operation, the user operates the motorized ice chute door
assembly
70 by pressing a glass, pitcher, or other similar container against an
actuator 78 or other
switch type device. The actuator 78 is shown to be an arm in Figure 10, but
may
alternately be a pad, button, or other mechanism. The actuator 78 can activate
an ice or
I 0 water dispenser, along with the opening of the ice chute door 21.
In one embodiment, the actuator 78 applies pressure against an actuator switch
80.
This requires little force from a user and thus is capable of allowing soft
type containers,
such as a Styrofoam cup, to be used with the dispenser 16. The actuator switch
80 closes
an electrical circuit which powers the motor 82. The motor 82 rotates a motor
gear 84
I 5 attached to the shaft of the motor 82. The motor gear 84, in turn, rotates
a worm gear 86.
The worm gear 86 mates with gears on a cam 88. The cam 88 thus rotates about a
cam
shaft 89 and is followed by a cam follower 90. The cam follower 90 follows the
peaks and
valleys on the cam 80 and is operatively connected to the ice chute door 21.
The ice chute
door 21 pivots along the hinge 74 with the cam follower 90 to open the ice
chute 20. Other
20 configurations or gear trains can be used so long as a motor drives them.
It is preferred that the cam 88 be constructed so that as the cam follower 90
follows
the peaks and valleys on the cam 88 so that the ice chute door 21 will open
and close with
the peaks and valleys of the cam 88. It is further preferred, but not
necessary, that the cam
88 be constructed with a cam notch 91 such that the cam follower 90 locks into
place so as
25 to hold the ice chute door 21 open until the container is disengaged from
the actuator arm
78, afterwhich the ice chute door 21 automatically closes. It is preferred
that the motorized
ice chute door assembly 70 be constructed to enclose the motor 82 with a motor
housing
cover 94.
As the ice chute door 21 opens, it comes in contact with the position switch
92,
30 which instructs the motor 82 to stop turning when the door reaches the
proper location. A
delay is provided in the control system of the refrigerator 10 using an
intelligent controller,
9
CA 02545021 2006-04-27
which then permits the motor 82 to release force upon the motor shaft, which
in turn,
permits the icc chute door spring 76 to close the ice chute door 21.
'hhe motorized chute extension door assembly 70 has advantages over a standard
solenoid which is used in many dispensers. Some of the benefits include
reduced size,
5 better control, permitting a spring biased chute door 21, lower power
consumption, reduced
electrical noise, and no door snap sound upon opening as with a solenoid. 1-
Iowever, the
primary benef t of a motorized ice chute door assembly 70 is reduced power
consumption
over a standard solenoid opened door at approximately 2 watts versus 20 watts.
The motorized ice chute door assembly 70 contemplated by this invention, can
use
10 any number of gears and/or cams so long as a motor is used for opening the
ice chute door
21.
The dispenser 16 of the current invention has an ice chute air seal 100, as
seen in
Figures 14 and 14A. The seal 100 is preferred to be made of a flexible
material compound
including components such as PVC (polyvinyl chloride), TPV (thermoplastic
vulcanizate),
15 MPR (melt-processable robber), TPU (thermoplastic urethane) or TPE
(thermoplastic
elastomer). Seal 100 can be made of any material providing compression and
expansion
properties in a form suitable for molding to a mating surface or extrusion in
the alternate
method of construction. 'The flexible material compound of which seal 100 is
comprised
may include additive such as Kemamide (stearyi erucamide) or PTFE
20 (polytetrafrouroethylene) to reduce the coefficient of friction and
therefore improve wear
resistance at the interface 100 of the seal and ice-box cover 106, or at the
interface of the
seal 100 and door liner 38 in an alternate method of construction.
In the present invention, the seal 100 is comprised of a flexible material
over-
molded upon a rigid plate (not shown) having a wand type cross-section and
attached to the
25 inner door liner 38. The seal 100 may also be comprised of a flexible,
extruded wand or
mufti-cavitied bellows profile and attached by means of a relatively rigid
plate (not shown),
or by other means to the inner door liner 38. Alternatively, the seal 100 may
be attached to
the ice compartment 106 cover. In the preferred embodiment of the invention,
the seal 100
is preferred to be attached to the door liner 38 by means of the rigid plate
snapping to the
30 top portion of the ice chute 102 with a friction fit. However, the seal 100
may also be
attached directly to the inner door liner 38.
CA 02545021 2006-04-27
The height of the seal 100 is sufficient to reduce the sensitivity of the
overall
design, with regard to the occurrence of an air leak at the breakable junction
104 between
the dispenser 16 and an ice compartment 106 located inside the refrigerator
10, due to
manufacturing variation.
5 In another embodiment of the seal 100, springs (not shown) can supply a
resistance
force around pegs (not shown) which support a plate (not shown) inserted into
the door
liner 38. The pegs allow for the swiping motion incurred during opening and
closing of the
refrigerator door 12, without displacing the seal 100. The seal 100 can
comprise multiple
parts, or can be a single part that stays in place with a friction fit.
10 The purpose of the seal 100 is to seal against air leakage at the breakable
junction
104. The door 21 can be opened and closed to gain access to the fresh food
compartment
12 or freezer compartment 14 inside the refrigerator 10. The ice compartment
temperature
is normally lower than the fresh food compartment temperature and at a higher
pressure.
The seal 100, located around a top portion of the ice chute 102, creates a
seal between the
1 S ice compartment 106 and the ice chute 20 in order to prevent air from
escaping the ice
compartment and causing temperature fluctuations, moisture and/or frost
buildup. The ice
chute air seal 100 can be of any shape or size and is preferred to be
replaceable. However,
the seal 100 should seal the air gap between the ice chute 20 and the ice
compartment 106.
Based on the above, it should be readily recognized that the forward
projecting
20 dispenser 16 provides an arrangement for dispensing ice and water that
enables the door 12
to include additional internal storage space, create the potential for filling
oversized
containers, reduce power consumption during ice dispensing, and reduce air
leakage
between the ice chute and the ice compartment more readily than the prior art.
Although
described with respect to the preferred embodiment of the invention, it should
be readily
25 apparent that various changes and/or modifications can be made to the
invention without
departing from the spirit thereof. In general, the invention is only intended
to be limited by
the scope of the following claims.
