Ice maker leak detection

Abstract

A method of operating an ice maker includes directing liquid water to a mold body of the ice maker. The method further includes determining that at least a portion of the liquid water escapes based on at least one of the ice making time, the harvest motor torque, or the rate of temperature change. The method further includes providing a user notification in response to determining that at least a portion of the liquid water escapes.

Description

Ice Maker Leak Detection Technical Field

[0001] The present invention relates generally to ice makers and, more particularly, to systems and methods for detecting leaks in such appliances. Background Art

[0002] Some refrigeration appliances include ice makers. Ice makers can also be stand-alone appliances designed for use in commercial and / or residential kitchens. To make ice, liquid water is directed to the ice maker and frozen. For example, some ice makers include a mold body for receiving the liquid water. After ice is formed in the mold body, the ice can be harvested from the mold body and stored in an ice bin or bucket within the refrigeration appliance.

[0003] In some cases, a certain amount of liquid water introduced into the mold body may escape from the mold body before ice is formed as intended. For example, the mold body may develop cracks, one or more sealing elements may wear, or the mold body may be overfilled. In one example of a possible overfilling scenario, in a twist-tray ice maker that includes a partitioned plastic mold that physically deforms to break the bond between the ice and the tray, ice cubes may break during the twisting process. When this breakage occurs, a portion of the ice cube may remain in the tray, resulting in overfilling during the next filling process.

[0004] Conditions that may result in liquid water escaping from the mold body are generally not readily observable to users of the ice making machine. Consequently, such conditions may persist for an extended period of time and / or result in a significant amount of water escaping from the ice making machine (such as a time and / or amount sufficient to exhibit secondary effects of the escaping water) before the user is even aware of the water escaping, let alone being able to remedy the problem.

[0005] Therefore, an ice making machine with improved leak detection features would be desirable.

[0006] Summary of the Invention

[0007] Various aspects and advantages of the invention are set forth below in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0008] According to an exemplary embodiment, a method for operating an ice maker is provided. The ice maker includes a mold body. The method includes directing liquid water to the mold body and calculating an ice making time after directing the liquid water to the mold body. The method also includes determining that the calculated ice making time is less than an allowable ice making time. Because the calculated ice making time is less than the allowable ice making time, it can be determined that at least a portion of the liquid water has escaped. The method also includes providing a user notification in response to determining that at least a portion of the liquid water has escaped.

[0009] According to another exemplary embodiment, a method of operating an ice maker is provided. The ice maker includes a mold body and a harvesting motor. The method includes directing liquid water to the mold body and, after directing the liquid water to the mold body, determining that ice has formed in the mold body. The method also includes harvesting ice from the mold body. Harvesting ice from the mold body includes activating the harvesting motor. The method also includes measuring a torque of the harvesting motor during harvesting ice from the mold body and determining that the measured torque of the harvesting motor is less than a minimum harvesting torque threshold. Because the measured torque of the harvesting motor is less than the minimum harvesting torque threshold, it can be determined that at least a portion of the liquid water has escaped. The method also includes providing a user notification in response to determining that at least a portion of the liquid water has escaped.

[0010] According to another exemplary embodiment, a method for operating an ice maker is provided. The ice maker includes a mold body and a temperature sensor operable to measure a temperature at the mold body. The method includes directing liquid water to the mold body and calculating a temperature change rate of the temperature of the mold body after directing the liquid water to the mold body. The method also includes determining that the calculated temperature change rate is greater than a maximum temperature change rate threshold. Because the calculated temperature change rate is greater than the maximum temperature change rate threshold, it can be determined that at least a portion of the liquid water has escaped. The method also includes providing a user notification in response to determining that at least a portion of the liquid water has escaped.

[0011] These and other features, aspects and advantages of the present invention will become more readily 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 present invention and, together with the description, serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] With reference to the accompanying drawings, the specification sets forth a complete disclosure of the present invention for those skilled in the art, which disclosure enables those skilled in the art to implement the present invention, including the best embodiment of the present invention.

[0013] FIG. 1 provides a perspective view of a refrigeration appliance according to an exemplary embodiment of the present invention.

[0014] 2 provides a perspective view of the exemplary refrigeration appliance of FIG. 1 , with the fresh food compartment door shown in an open position.

[0015] FIG. 3 provides an interior perspective view of a dispenser door of the exemplary refrigeration appliance of FIG. 1 .

[0016] 4 provides an interior elevational view of the door body of FIG. 3 , with the access door of the door body shown in an open position.

[0017] 5 provides a perspective view of an exemplary ice maker disposed in an ice bin according to one or more embodiments of the present invention.

[0018] FIG. 6 provides another perspective view of the exemplary ice maker of FIG. 5 .

[0019] FIG. 7 provides a schematic diagram of components of an ice maker according to one or more embodiments of the present invention.

[0020] FIG8 provides a schematic diagram of components of an ice maker according to one or more additional embodiments of the present invention.

[0021] FIG. 9 provides a flow chart illustrating an exemplary method of operating an ice maker according to one or more embodiments of the present invention.

[0022] FIG. 10 provides a flow chart illustrating another exemplary method of operating an ice maker according to one or more additional embodiments of the present invention.

[0023] 11 provides a flow chart illustrating yet another exemplary method of operating an ice maker according to one or more additional embodiments of the present invention.

[0024] Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention. DETAILED DESCRIPTION

[0025] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are shown in the accompanying drawings. Each example is provided in an illustrative manner and does not limit the present invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the scope or spirit of the present invention. For example, a feature shown or described as part of one embodiment can be used in another embodiment, thereby producing yet another embodiment. Therefore, it is intended that the present invention covers these modifications and variations within the scope of the appended claims and their equivalents.

[0026] As used herein, approximate terms such as "substantially" or "approximately" include values ​​within ten percent greater or less than the stated value. When used in the context of an angle or direction, such terms include values ​​within ten degrees greater or less than the stated angle or direction. For example, "substantially vertical" includes directions within ten degrees of a vertical line in any direction (e.g., clockwise or counterclockwise). As used herein, the terms "first," "second," and "third" may be used interchangeably to distinguish one component from another, and these terms are not intended to indicate the position or importance of each component.

[0027] FIG1 provides a perspective view of a refrigeration appliance 100 according to an exemplary embodiment of the present invention. The refrigeration appliance 100 includes a housing or casing 102 that extends along a vertical direction V between a top 104 and a bottom 106, along a lateral direction L between a first side 108 and a second side 110, and along a lateral direction T between a front side 112 and a rear side 114. Each of the vertical direction V, the lateral direction L, and the lateral direction T is perpendicular to one another.

[0028] The housing 102 defines a refrigeration compartment for receiving food for storage. Specifically, the housing 102 defines a fresh food compartment 122 disposed at or adjacent to the top 104 of the housing 102 and a freezer compartment 124 disposed at or adjacent to the bottom 106 of the housing 102. As can be seen, the refrigeration appliance 100 is commonly referred to as a bottom-mounted refrigerator. However, it is recognized that the benefits of the present invention are applicable to other types and styles of refrigeration appliances, such as top-mounted refrigeration appliances, side-by-side refrigeration appliances, or single-door refrigeration appliances. Therefore, the description set forth herein is for illustrative purposes only and is not intended to limit any particular refrigeration compartment configuration in any respect.

[0029] A refrigerator door 128 is rotatably hinged to the edge of the housing 102 for selective access to the fresh food compartment 122. In addition, a freezer door 130 is disposed below the refrigerator door 128 for selective access to the freezer compartment 124. The freezer door 130 is coupled to a freezer drawer (not shown) slidably mounted within the freezer compartment 124. The refrigerator door 128 and the freezer door 130 are shown in a closed configuration in FIG1 . Those skilled in the art will appreciate that other compartment and door configurations are feasible and within the scope of the present invention.

[0030] Fig. 2 provides the three-dimensional view of the refrigeration appliance 100 shown when the refrigeration door body 128 is in the open position.As shown in Figure 2, as will be understood by those skilled in the art, various storage components are installed in the fresh food compartment 122, to promote the storage of food therein.Particularly, the storage component can include a box 134 and a shelf 136.Each of these storage components is used to receive food (for example, beverages or / or solid foods etc.), and can assist in organizing this food.As shown, box 134 can be installed on the refrigeration door body 128 or can slide into the accommodation space in the fresh food compartment 122.Should be understood that the storage component shown is only for illustrative purposes, and other storage components can be used, and other storage components can have different sizes, shapes and structures.

[0031] Referring now generally to FIG1 , a dispensing assembly 140 according to an exemplary embodiment of the present invention will be described. Dispensing assembly 140 is generally used to dispense liquid water and / or ice. While an exemplary dispensing assembly 140 is illustrated and described herein, it should be understood that various changes and modifications may be made to dispensing assembly 140 while remaining within the scope of the present invention.

[0032] The dispensing assembly 140 and its various components can be at least partially disposed within a dispenser recess 142 defined on one of the refrigeration doors 128. In this regard, the dispenser recess 142 is defined on the front side 112 of the refrigeration appliance 100, allowing the user to access the dispensing assembly 140 without opening the refrigeration door 128. Furthermore, the dispenser recess 142 is positioned at a predetermined height that facilitates user access to ice and enables the user to access ice without bending over. In an exemplary embodiment, the dispenser recess 142 is positioned approximately at chest level.

[0033] Dispensing assembly 140 includes an ice dispenser 144 including a discharge port 146 for discharging ice from dispensing assembly 140. An actuation mechanism 148, shown as a paddle, is mounted below discharge port 146 to operate ice or water dispenser 144. In alternative exemplary embodiments, any suitable actuation mechanism can be used to operate ice dispenser 144. For example, ice dispenser 144 can include a sensor (such as an ultrasonic sensor) or a button instead of a paddle. Discharge port 146 and actuation mechanism 148 are external parts of ice dispenser 144 and are mounted in dispenser recess 142.

[0034] In contrast, within the refrigeration appliance 100, the refrigeration door 128 may define an ice bin 150 (FIGS. 2-4) housing an ice maker 200 and an ice bank 202 configured to supply ice to the dispenser recess 142. In this regard, for example, the ice bin 150 may define an ice making chamber 154 for housing an ice making assembly, a storage mechanism, and a dispensing mechanism.

[0035] A control panel 160 is provided to control the operating mode. For example, the control panel 160 includes one or more selection inputs 162, such as knobs, buttons, a touch screen interface, and the like, such as a water dispensing button and an ice dispensing button, for selecting a desired operating mode, such as crushed ice or non-crushed ice. Furthermore, the inputs 162 can be used to specify a fill volume or a method for operating the dispensing assembly 140. In this regard, the inputs 162 can communicate with a processing device or controller 164. Signals generated in the controller 164 in response to the selector inputs 162 operate the refrigeration appliance 100 and the dispensing assembly 140. Furthermore, a display 166, such as an indicator light or a screen, can be provided on the control panel 160. The display 166 can communicate with the controller 164 and display information in response to signals from the controller 164.

[0036] As used herein, "processing device" or "controller" may refer to one or more microprocessors or semiconductor devices and is not necessarily limited to a single element. The processing device can be programmed to operate the refrigeration appliance 100 and the distribution assembly 140. The processing device may include or be associated with one or more storage elements (e.g., permanent storage media). In some such embodiments, the storage element includes an electrically erasable programmable read-only memory (EEPROM). Typically, the storage element can store information accessible to the processing device, including instructions that can be executed by the processing device. Alternatively, the instructions can be software or any set of instructions and / or data that, when executed by the processing device, causes the processing device to perform an operation.

[0037] Referring now to Figures 3 and 4, Figure 3 provides an interior perspective view of a refrigeration door 128, and Figure 4 provides an interior elevation view of the door 128, wherein the access door 170 is shown in an open position. The refrigeration appliance 100 includes a sub-compartment 150 defined on the refrigeration door 128. As described above, the sub-compartment 150 can be referred to as an "ice box." In the illustrated exemplary embodiment, when the refrigeration door 128 is in the closed position, the ice box 150 extends into the food freshness compartment 122. As shown in Figure 4, an ice maker 200 can be disposed within the ice box 150. The ice maker 200 is typically used to freeze water to make ice (e.g., block ice, such as ice cubes), which can be stored in an ice storage bin 202 and dispensed via a dispensing assembly 140 via a discharge port 146. FIG4 illustrates an ice maker 200 with an ice bank 202 positioned below the ice maker 200 for receiving ice cubes from the ice maker 200, for example, after the ice has been discharged from the ice maker 200. As will be appreciated by those skilled in the art, ice from the ice maker 200 is collected and stored in the ice bank 200 and supplied to the dispenser 144 ( FIG1 ) from the ice bank 202 in the ice bin 150 on the back of the refrigeration door 128. Cool air from the sealed system (not shown) of the refrigeration appliance 100 can be directed to components within the ice bin 150 (e.g., the ice maker 200 and / or the ice bank 202).

[0038] As described above, the present invention can also be applied to other types and styles of refrigeration appliances, such as top-mounted refrigeration appliances, side-by-side refrigeration appliances, or stand-alone ice makers. Changes and modifications can be made to the ice maker 200 while remaining within the scope of the present invention. Therefore, the description herein of the ice tray 150 on the door 128 of the fresh food compartment 122 is merely exemplary. In other exemplary embodiments, the ice maker 200 can be located in the freezer compartment 124 of, for example, a bottom-mounted refrigerator, a side-by-side refrigerator, a top-mounted refrigerator, or any other suitable refrigeration appliance. As another example, the ice maker 200 can also be located in a stand-alone ice maker. As used herein, the term "stand-alone ice maker" refers to an appliance whose sole or primary operation is to generate or produce ice, while the more general term "ice maker" includes such appliances as well as appliances with different capabilities besides ice making, such as refrigeration appliances equipped with an ice maker, as well as other possible examples.

[0039] As described above, the access door 170 can be hinged to the interior of the refrigeration door body 128. The access door 170 allows selective access to the ice bin 150. A suitable latch 172 of any type can be configured with the ice bin 150 to maintain the access door 170 in a closed position. As an example, the latch 172 can be actuated by the consumer to open the access door 170 to provide access to the ice bin 150. The access door 170 can also assist in isolating the ice bin 150, for example, by thermally isolating or insulating the ice bin 150 from the fresh food compartment 122.

[0040] Referring now to Figures 5 and 6, a perspective view of an exemplary embodiment of an ice maker 200 is illustrated. In some embodiments, for example, as illustrated in Figures 5 and 6, the ice maker 200 can be a twist tray ice maker. In such an embodiment, the ice maker 200 may include a mounting unit 210 that is disposed in the ice bin 150, for example, mounted on one or more interior surfaces of the ice bin 150. The mounting unit 210 may be coupled to an ice tray 220, for example, the mounting unit 210 may be configured to releasably receive the ice tray 220. The ice tray 220 may provide a mold body for the ice maker 200, for example, the ice tray 220 may include one or more compartments 224 for receiving liquid water therein, and the liquid water may be retained in the compartments 224 until ice is formed (or at least a portion of the liquid water may be retained). The ice tray 220 may include a flexible (e.g., twistable) material, such as the ice tray 220 may include a plastic material that is flexible enough to twist the ice tray 220 to facilitate detachment, e.g., release, of ice cubes in the ice tray 220, as understood by those of ordinary skill in the art.

[0041] In some embodiments, the mounting unit 210 may include a first mounting unit 211 and a second mounting unit 212. The mounting units 211 and 212 may be spaced apart from each other along the central axis 201 of the ice maker 200. In various embodiments, when the ice tray 220 is mounted to the mounting unit 210, the direction of the central axis 201 corresponds to (e.g., along or parallel to) the longitudinal axis of the ice tray 220. Furthermore, the mounting units 211 and 212 may be spaced apart from each other to allow a pair of lips 222 ( FIG. 6 ) of the ice tray 220, separated along the central axis 201, to be received by the respective mounting units 211 and 212. For example, the mounting unit 210 may include one or more clips 218, for example, a first clip 218 on the first mounting unit 211 and a second clip 218 on the second mounting unit 212, and the lip 222 of the ice tray 220 may be configured to be received within and retained by the clips 218, for example, the lips 222 may each be sized and shaped to correspond to the corresponding clips 218, such as the outer dimensions of the lip 222 or each lip 222 may correspond to the inner dimensions of the clip 218 or each clip 218, whereby the lip 222 may be received within and retained by the clip 218.

[0042] In various embodiments, the mounting unit 210 includes a rotor 216 configured to rotate relative to the central axis 201. In such embodiments, the first clip 218 on the first mounting unit 211 can be integrally formed with the rotor 216. The first mounting unit 211 can be secured to the ice bin 150. The first mounting unit 211 can include a motor or other actuator 206 operably coupled to the rotor 216 to rotate relative to (e.g., around) the central axis 201. When the ice tray 220 is mounted on the rotor 216, rotation of the rotor 216 (e.g., by the actuator 206) causes the ice tray 220 to pour or deposit ice or other contents from the ice tray 220.

[0043] In some embodiments, the ice maker 200 may include a dedicated controller 207, for example, similar to the controller 164 of the refrigeration appliance 100 described above. In embodiments where the ice maker 200 is incorporated into a refrigeration appliance (such as the exemplary refrigeration appliance 100 described above), the dedicated controller 207 may be in addition to the controller 164 of the refrigeration appliance and may communicate with the controller 164 of the refrigeration appliance 100. The controller 207 of the ice maker 200 may be in operable communication with other components of the ice maker 200 and may be specifically used to control or direct the operation of such components (e.g., the actuator 206). In some embodiments, the ice maker 200 may also include one or more sensors, such as a temperature sensor, as will be further described below, and the dedicated controller 207 of the ice maker 200 may also be in operable communication with these sensors.

[0044] For example, controller 207 may cause actuator 206 to rotate a first amount, e.g., a first degree, about central axis 201 to twist tray 220 to facilitate release of ice cubes from compartments 224 thereof, such as by rotating the first amount in a first direction and then rotating the same amount, e.g., a first amount, in a second direction opposite the first direction to twist tray 220 to release ice cubes from compartments 224. After rotating the first amount, e.g., after twisting tray 220, controller 207 may then cause actuator 206 to rotate a second amount, e.g., a second degree, about central axis 201 that is greater than the first amount to tip or invert tray 220, thereby allowing ice cubes to fall from tray 220, e.g., by gravity, into bin 202 ( FIG. 4 ) below ice maker 200.

[0045] FIG7 and FIG8 provide schematic diagrams of various embodiments of an ice making machine 200 according to the present invention. As can be seen in FIG7 and FIG8 , ice making machine 200 may include or be provided with a water conduit 230 that is arranged and configured to direct a flow of liquid water to a mold body 236 of ice making machine 200. For example, the flow of liquid water may be directed to and / or enter mold body 236. For example, mold body 236 may be tray 220 described above with respect to FIG5 and FIG6 , or any other suitable mold body 236 for receiving and holding liquid water for forming ice blocks (such as ice cubes, ice gems, etc.) therein. Ice making machine 200 may also include a temperature sensor 238. Temperature sensor 238 is configured to measure the temperature of mold body 236 and / or an object (such as liquid water and / or solid water) within mold body 236. Temperature sensor 238 may be any suitable device for measuring the temperature of mold body 236 and / or an object therein. For example, temperature sensor 238 may be a thermistor, a thermocouple, or a bimetallic device. Controller 207 ( FIG. 6 ) can receive a signal, such as a voltage or current, from temperature sensor 238 that corresponds to the temperature of mold body 236 and / or the object therein. Thus, the temperature of mold body 236 and / or the object therein can be monitored and / or recorded by controller 207. Some embodiments can also include an electromechanical ice maker configured with a bimetallic device to complete an electrical circuit when a specific temperature is reached.

[0046] 7 , in some embodiments, a flow meter 232 can be disposed in the water conduit 230. Thus, the amount (e.g., volume) of liquid water provided to the mold body 236 can be directly measured, for example, by or using the flow meter 232. For example, the flow meter 232 can be in operative communication with the controller 207 and / or can be communicatively coupled with the controller 207 to transmit a signal indicative of or corresponding to the flow rate of liquid water through the water conduit 230 and to the mold body 236, as measured by the flow meter 232, in a manner similar to that described above with respect to the temperature sensor 238.

[0047] Now referring specifically to FIG. 8 , in some embodiments, a water filter 234 can be disposed within the water conduit 230 , e.g., coupled to the water conduit and / or connected in series therewith. Thus, liquid water flowing through the water conduit 230 and reaching the mold body 236 can also flow through the filter 234 , e.g., upstream of the mold body 236 , such that the liquid water flows through the filter 234 before being delivered to the mold body 236 . In such embodiments, the ice maker 200 (e.g., its controller 207 ) can be operable and configured to monitor or query the status of the water filter 234 , such as the lifespan of the water filter 234 . For example, the water filter 234 can be removably coupled to the water conduit 230 , such that the water filter 234 can be periodically removed and replaced, such as after a predetermined period of several months following the initial installation of the water filter. For example, the water filter 234 can have a lifespan of approximately six months.

[0048] Turning now to Figures 9-11, embodiments of the present invention may include methods of operating an ice maker, such as the exemplary ice maker 200 described above.

[0049] As shown in FIG9 , method 900 may include directing liquid water to the mold body, for example, as indicated at 910 in FIG9 . After directing the liquid water to the mold body, method 900 may include calculating 920 an ice making time, which is, for example, the amount of time it takes for the liquid water (or at least as much liquid water as is actually received and retained in the mold body) to transform into ice within the mold body. For example, the ice making time may be calculated by monitoring the temperature at the mold body, for example, by directly measuring the mold body temperature with a temperature sensor in direct contact with the mold body, or by measuring the ambient temperature in the area immediately surrounding the mold body, from which the mold body temperature may be inferred, and tracking the time until the monitored temperature reaches a level indicative of ice formation (such as approximately 32 degrees Fahrenheit or less), where such a level may also be an ice making threshold. The ice making time may also be calculated based on how long the monitored temperature remains at or below a level indicative of ice formation (such as when the monitored temperature remains at or below that level for at least a minimum time) and / or based on a time-temperature integral, as will be further described below.

[0050] In some embodiments, given a known volume of ice to be produced, such as based on the volume of the mold body, for example, the volume of compartment 224 in embodiments where the mold body is provided as an ice tray 220, an expected or allowed ice making time can be determined. The expected or allowed ice making time can also be based on the volume of liquid water provided to the mold body, for example, the volume of liquid water referenced at 910 in FIG. 9 , where the volume of liquid water can be determined or measured in various ways as described below. For example, the allowed ice making time can be a minimum time, for example, the shortest amount of time a known volume of liquid water can freeze, for example, given an expected starting temperature of the liquid water provided to the mold body and an operating temperature of the cooling system of the ice maker. Thus, in some embodiments, method 900 can further include determining that the ice making time calculated from step 920 is less than the allowed ice making time, for example, as indicated at 930 in FIG. 9 . When the actual ice making time (e.g., the calculated ice making time) is shorter than expected (e.g., less than the allowed ice making time), it can be inferred that the volume of liquid water frozen during the calculated ice making time is less than the expected water volume, e.g., less than the volume of water directed to the mold body in step 910. Therefore, when less than all of the water directed to the mold body ultimately turns into ice, the amount of water that did not freeze may have escaped from the mold body. Liquid water may escape from the mold body in one or more of a variety of ways, such as not reaching the mold body at all, e.g., due to misalignment of the fill conduit with the mold body or deformation or blockage of the fill conduit, resulting in erratic flow from the fill conduit (e.g., some liquid water may have been ejected from the fill conduit outside the mold body, e.g., some liquid water may have been directed to the mold body but then diverged from the path before reaching the mold body). As another example, liquid water may escape from the mold body by overflow, such as when the mold body is partially blocked, e.g., by remnants of previously formed ice therein, or by leaking, e.g., from cracks in the mold body.

[0051] As another example, in some embodiments, method 900 may further include, after detecting escaping water, sending a user notification, for example, to a display on the ice maker and / or to a remote user interface device, as exemplified in step 950 of FIG. 9 . For example, in embodiments where the ice maker is a refrigeration appliance (such as refrigeration appliance 100) having an ice maker therein, controller 207 of ice maker 200 may communicate with controller 164 of refrigeration appliance 100, whereby the user notification may be displayed on a user interface of refrigeration appliance 100, such as display 166 ( FIG. 1 ). In exemplary embodiments where the user notification is also or alternatively provided on a remote user interface device, the remote user interface device may be any suitable device, such as a laptop, smartphone, tablet, personal computer, wearable device, smart speaker, smart home system, and / or various other suitable devices. The remote user interface device is "remote" in that it is at least separate from the ice maker and not physically connected to the ice maker. For example, the remote user interface device is a standalone device separate from the ice maker that wirelessly communicates with the ice maker via various possible communication connections and interfaces, such as Wi-Fi. The ice maker and the remote user interface device can be matched in wireless communication, for example, connected to the same wireless network. The ice maker can communicate with the remote user interface device via a short-range radio such as Bluetooth or any other suitable wireless network with a layer protocol architecture. Any suitable device separate from the ice maker that is configured to provide and / or receive communications, information, data or commands from a user can be used as the remote user interface device, such as a smart phone, smart watch, personal computer, smart home system or other similar device. For example, the remote user interface device can be a smart phone that is operable to store and run an application (also referred to as an "app"), and some or all of the method steps disclosed herein can be performed by the smart phone application. For example, the user notification can be or include an email, text message and / or other suitable notification via the remote user interface device.

[0052] As described above, the allowed ice making time may be proportional to or based on the volume of liquid water directed to the mold body. For example, in some embodiments, the ice maker may include a flow meter, such as described above with respect to FIG. 7 . In such embodiments, the method may further include measuring the flow rate of the liquid water while directing the liquid water to the mold body, and determining the volume of the liquid water based on the measured flow rate, wherein the allowed ice making time is based on the determined volume of the liquid water. In other embodiments, the ice maker may also or alternatively include a water filter, such as described above with respect to FIG. 8 . In such embodiments, the method may further include determining the condition of the water filter, wherein the allowed ice making time is based on the determined condition of the water filter. For example, the condition of the water filter may include the lifespan of the water filter, and the flow rate of the liquid water directed to the mold body may be determined based on the lifespan of the filter, such as, for example, where an older filter becomes more clogged, thereby providing a reduced flow of water through the filter to the mold body. In some embodiments, the method may include determining a flow rate of liquid water based on a state of the water filter, and determining a volume of liquid water based on the determined flow rate, such as determining the volume of liquid water directed to the mold body based on the determined flow rate multiplied by the flow time.

[0053] FIG10 illustrates another exemplary method of operating an ice maker according to one or more embodiments of the present invention. The ice maker may include a mold body and a harvesting motor. For example, tray 220 may be an embodiment of the mold body, and actuator 206 may be an embodiment of the harvesting motor. As shown in FIG10 , exemplary method 1000 may include step 1010 of directing liquid water to the mold body, for example, as described above with respect to step 910 of method 900.

[0054] Method 1000 may also include determining that ice has formed in the mold body after directing the liquid water to the mold body, for example, as indicated at 1020 in FIG. For example, determining that ice has formed may be based on a time and / or temperature after directing the liquid water to the mold body. In some embodiments, the ice maker may include a temperature sensor. In such embodiments, the method may also include monitoring the temperature at the mold body with the temperature sensor, wherein determining that ice has formed in the mold body may be based on the monitored temperature reaching an ice formation threshold, and / or based on the monitored temperature remaining at or below the ice formation threshold, and / or based on a time-temperature integral, as further described below.

[0055] Once ice formation has been detected or determined, method 1000 may include harvesting ice from the mold body 1030. For example, harvesting ice from the mold body may include activating a harvesting motor of an ice maker.

[0056] Method 1000 may also include, for example, measuring the torque of the harvesting motor during harvesting of ice from the mold body 1040. The torque provided may be generally proportional to the volume of ice formed (e.g., the extent to which the volume of liquid water directed to the mold body actually reaches the mold body and remains therein throughout the freezing process). Thus, when the torque during harvesting is less than expected, this may indicate that less ice is formed than expected, e.g., less than all of the volume of liquid water directed to the mold body ultimately becomes ice. For example, method 1000 may also include determining that the measured torque of the harvesting motor is less than a minimum harvesting torque threshold (1050), and determining that at least a portion of the liquid water escaped based on the measured torque of the harvesting motor being less than the minimum harvesting torque threshold (1060).

[0057] For example, in embodiments where the mold body includes an ice tray (e.g., a twisting tray as described above with reference to Figures 5 and 6 ), harvesting ice from the mold body may include twisting the ice tray, and the measured torque of the harvesting motor may include the torque applied while twisting the ice tray. For example, when less ice has escaped from the ice tray, the ice tray may be more easily twisted. Also by way of example, when the ice tray is cracked, the ice tray may be more easily twisted (e.g., less torque applied by the harvesting motor to twist the ice tray), and such cracks in the ice tray may also allow liquid water to escape from the mold body (e.g., from the ice tray, which in such embodiments may be a mold body).

[0058] Thus, for example, leaks as described above or other water escape events such as overfilling, fill pipe misalignment, etc. can be detected based on the harvesting motor torque. Further, method 1000 can also include providing a user notification in response to determining that at least a portion of the liquid water has escaped, for example, as indicated at (1070) in Figure 10. As described above with respect to method 900, the user notification can be provided on an interface (e.g., a display) of the ice maker itself and / or on a remote user interface device.

[0059] In various embodiments, determining that ice has formed in the mold body can be based on the volume of water that flows during the step of introducing a volume of liquid water to the mold body. Thus, given a specific temperature and / or a specific amount of time after introducing the liquid water to the mold body, it can be determined that the volume of liquid water has frozen.

[0060] In some embodiments, the ice maker may include a flow meter. In such embodiments, the method may further include measuring a flow rate of the liquid water with the flow meter while directing the liquid water to the mold body, and determining a volume of the liquid water based on the measured flow rate. Also in such embodiments, determining that ice has formed in the mold body may be based on the determined volume of the liquid water.

[0061] In some embodiments, the ice maker may include a water filter. In such embodiments, the method may further include determining the status of the water filter, such as the lifespan or maintenance status of the water filter. As described above, the status of the water filter may also indicate the flow rate of water passing therethrough. Thus, in such embodiments, determining that ice has formed in the mold body may be based on the status of the water filter. For example, such embodiments may include determining the flow rate of liquid water based on the status of the water filter (e.g., the lifespan of the water filter), and determining the volume of liquid water based on the determined flow rate. In such embodiments, determining that ice has formed in the mold body may be based on the determined volume of liquid water.

[0062] In some embodiments, the ice maker may include a temperature sensor. In such embodiments, the method may further include monitoring the temperature of the mold body with the temperature sensor, and determining that ice has formed in the mold body may be based on the monitored temperature, such as when the monitored temperature reaches an ice-forming threshold. In some embodiments, determining that ice has formed in the mold body may be based on temperature (e.g., the monitored temperature) and time (e.g., based on the temperature over time). For example, determining that ice has formed may be based on the monitored temperature being at or below the ice-forming threshold for at least a minimum ice-forming time. As another example, determining that ice has formed may be based on a time-temperature integral, such as the area under a temperature-over-time curve. In embodiments where determining that ice has formed is based on an integral of temperature over time, the integral may begin at a certain point in time and continue until the integral reaches a threshold, such as an ice-forming threshold, where the ice-forming threshold in such embodiments may be a time-temperature integral value. For example, the specific point in time at which the integral begins may be when the monitored temperature reaches a limit temperature, such as approximately 32 degrees Fahrenheit (32°F).

[0063] Referring now to FIG11 , there is illustrated another exemplary method 1100. As shown, exemplary method 1100 may include directing liquid water to a mold body, for example, as indicated at 1110 in FIG11 . Method 1100 may also include calculating 1120 a rate of temperature change of the temperature of the mold body (e.g., as measured by a temperature sensor) after directing the liquid water to the mold body.

[0064] When the temperature drops too quickly, the thermal mass present in the mold body may be less than expected. For example, the amount of liquid water directed to the mold body that is actually received and retained in the mold body may be less than the total amount of liquid water directed to the mold body. Thus, for example, an exemplary method according to the present invention may include determining that a calculated rate of temperature change is greater than a maximum temperature rate of change threshold, e.g., as indicated at 1130 in FIG. 11 . When the rate of temperature change is greater than the maximum temperature rate of change threshold, this may indicate that at least a portion of the liquid water has escaped, e.g., has never reached and / or escaped from the mold body. Accordingly, some embodiments may include determining 1140 that at least a portion of the liquid water has escaped based on the calculated rate of temperature change being greater than the maximum temperature rate of change threshold.

[0065] 11 , method 1100 may further include providing a user notification in response to determining that at least a portion of the liquid water has escaped 1150. As described above with respect to method 900, the user notification may be provided on the user interface of the ice maker and / or may be transmitted from the ice maker to a remote user interface device.

[0066] In some embodiments, the ice maker may include a flow meter. In such embodiments, the method may further include measuring a flow rate of the liquid water while directing the liquid water to the mold body, and determining a volume of the liquid water based on the measured flow rate. For example, the maximum temperature change rate threshold may be based on the determined volume of the liquid water.

[0067] In some embodiments, the ice maker may include a water filter. In such embodiments, the method may further include determining a condition of the water filter, such as the lifespan of the water filter. Also in such exemplary embodiments, the maximum temperature change rate threshold may be based on the determined condition of the water filter. For example, the method may further include determining a flow rate of the liquid water based on the condition of the water filter, and determining a volume of the liquid water based on the determined flow rate, and the maximum temperature change rate threshold may be based on the determined volume of the liquid water.

[0068] In some embodiments, the maximum temperature rate of change threshold can be based on a stored temperature rate of change from a previous operating cycle of the ice maker. For example, the previous operating cycle can be an initial cycle when the ice maker is first put into use (e.g., when first installed at the location of use). Thus, when the temperature rate of change threshold is calculated based on the actual operating cycle of the ice maker, the ice maker can be brand new, and thus the temperature rate of change threshold can be an optimal or ideal temperature rate of change. In some embodiments, the maximum temperature rate of change threshold can be a percentage of the temperature rate of change from the previous operating cycle, such as approximately one hundred and five percent (105%) or more, such as approximately one hundred and ten percent (110%), such as approximately one hundred and twenty-five percent (125%), of the measured and stored temperature rate of change from the previous operating cycle. As another example, the maximum temperature rate of change threshold can be based on additional stored temperature rates of change from additional previous operating cycles of the ice maker, such as an average temperature rate of change over multiple previous operating cycles. Thus, in some embodiments, the maximum temperature rate of change threshold can be customized for a specific ice maker unit and its installation and operating conditions.

[0069] In some embodiments, the maximum temperature change rate threshold can be a fixed, predetermined value. For example, the maximum temperature change rate threshold can be a pre-programmed factory setting for the ice maker. This embodiment can advantageously reduce the likelihood of false negatives, for example, when a leak develops very slowly over time and gradually deviates from the actual temperature change rate, and can provide a simpler algorithm with relatively low storage and processing requirements.

[0070] Referring now generally to Figures 9-11, methods 900, 1000, and / or 1100 may be interrelated and / or may have one or more steps from any one of methods 900, 1000, and / or 1100 combined with any other method 900, 1000, and / or 1100.

[0071] This written description uses examples to disclose the invention (including the best mode) and also to enable those skilled in the art to practice the invention (including making and using any device or system and performing any method included). The patentable scope of the invention is defined by the claims and may include other examples that occur to those skilled in the art. If such other examples include structural elements that do not differ from the literal language of the claims, or if such other examples include equivalent structural elements that do not differ substantially from the literal language of the claims, such other examples are intended to fall within the scope of the claims.

Claims

1. A method for operating an ice maker, characterized in that: The ice maker includes a mold body, and the method includes: directing liquid water to the mold body; calculating an ice making time after directing the liquid water to the mold body; determining that the calculated ice-making time is less than an allowed ice-making time; determining that at least a portion of the liquid water has escaped based on the calculated ice making time being less than the allowed ice making time; and A user notification is provided in response to determining that the at least a portion of the liquid water escaped.

2. The method according to claim 1, characterized in that The ice maker further includes a flow meter, and the method further includes measuring a flow rate of the liquid water while directing the liquid water to the mold body, and determining a volume of the liquid water based on the measured flow rate, wherein the allowed ice making time is based on the determined volume of the liquid water.

3. The method according to claim 1, characterized in that The ice maker further includes a water filter, and the method further includes determining a status of the water filter, wherein the allowed ice making time is based on the determined status of the water filter.

4. The method according to claim 3, characterized in that The method further includes determining a flow rate of the liquid water based on the state of the water filter, and determining a volume of the liquid water according to the determined flow rate.

5. The method according to claim 1, wherein The ice maker further includes a temperature sensor, wherein calculating the ice making time includes monitoring a temperature at the mold body using the temperature sensor and calculating a time until the monitored temperature reaches an ice making threshold.

6. A method for operating an ice maker, characterized in that: The ice maker includes a mold body and a harvesting motor, and the method includes: directing liquid water to the mold body; determining that ice has formed in the mold body after directing the liquid water to the mold body; harvesting the ice from the mold body, wherein harvesting the ice from the mold body comprises activating the harvesting motor; measuring a torque of the harvesting motor during harvesting of the ice from the mold body; determining that the measured torque of the harvesting motor is less than a minimum harvesting torque threshold; The liquid is determined based on the measured torque of the harvesting motor being less than the minimum harvesting torque threshold. at least a portion of the water escapes; and A user notification is provided in response to determining that the at least a portion of the liquid water escaped.

7. The method according to claim 6, characterized in that The ice maker further includes a flow meter, the method further including measuring a flow rate of the liquid water while directing the liquid water to the mold body, and determining a volume of the liquid water based on the measured flow rate, and wherein determining that ice has been formed in the mold body is based on the determined volume of the liquid water.

8. The method according to claim 6, characterized in that The ice maker further includes a water filter, the method further including determining a status of the water filter, wherein determining that ice has formed in the mold body is based on the status of the water filter.

9. The method according to claim 8, characterized in that Also included is determining a flow rate of the liquid water based on the state of the water filter, and determining a volume of the liquid water based on the determined flow rate, wherein determining that ice has formed in the mold body is based on the determined volume of the liquid water.

10. The method according to claim 6, characterized in that The ice maker further includes a temperature sensor, and the method further includes monitoring a temperature at the mold body using the temperature sensor, wherein determining that ice has formed in the mold body is based on the monitored temperature reaching an ice making threshold.

11. The method according to claim 6, characterized in that The ice maker further includes a temperature sensor, the method further including monitoring a temperature at the mold body using the temperature sensor, wherein determining that ice has formed in the mold body is based on the monitored temperature over time.

12. The method according to claim 6, characterized in that The mold body includes an ice tray, wherein harvesting the ice from the mold body includes twisting the ice tray, and wherein the measured torque of the harvesting motor includes torque while twisting the ice tray.

13. A method of operating an ice maker, characterized in that: The ice maker includes a mold body and a temperature sensor operable to measure a temperature at the mold body, the method comprising: directing liquid water to the mold body; calculating a temperature change rate of the mold body's temperature after introducing the liquid water to the mold body; determining that the calculated temperature change rate is greater than a maximum temperature change rate threshold; determining that at least a portion of the liquid water has escaped based on the calculated rate of temperature change being greater than the maximum temperature rate of change threshold; and A user notification is provided in response to determining that the at least a portion of the liquid water escaped.

14. The method according to claim 13, characterized in that The ice maker further includes a flow meter, and the method further includes measuring a flow rate of the liquid water while directing the liquid water to the mold body, and determining a volume of the liquid water based on the measured flow rate, wherein the maximum temperature change rate threshold is based on the determined volume of the liquid water.

15. The method according to claim 13, characterized in that The ice maker further includes a water filter, and the method further includes determining a status of the water filter, wherein the maximum temperature change rate threshold is based on the determined status of the water filter.

16. The method according to claim 15, characterized in that The method further includes determining a flow rate of the liquid water based on the state of the water filter, and determining a volume of the liquid water according to the determined flow rate, wherein the maximum temperature change rate threshold is based on the determined volume of the liquid water.

17. The method according to claim 13, wherein The maximum temperature change rate threshold is based on stored temperature change rates from previous operating cycles of the ice maker.

18. The method according to claim 13, characterized in that The maximum temperature change rate threshold is a fixed predetermined value.

Images