US20260016211A1

US20260016211A1 - Ice maker leak response shutoff kit

Info

Publication number: US20260016211A1
Application number: US19/334,005
Authority: US
Inventors: Kevin Knatt
Original assignee: True Manufacturing Co Inc
Current assignee: True Manufacturing Co Inc
Priority date: 2025-09-19
Filing date: 2025-09-19
Publication date: 2026-01-15

Abstract

The present disclosure provides a kit for an ice maker, an assembly of the ice maker and kit components, and methods of installing the kit and operating the ice maker. The kit includes an overflow pan, a sensor, and an external water supply valve. In use, the overflow pan is positioned below the cabinet, and the sensor is positioned in the overflow pan for detecting water in the overflow pan. The sensor is communicatively connected to the ice maker's controller. The external water supply valve is fluidly connected to the water system upstream of the ice maker and communicatively connected to the controller. The controller actuates the external water supply valve to shut off water supply to the ice maker in response to the sensor detecting water in the overflow pan.

Description

FIELD OF INVENTION

The present disclosure relates to ice maker leak detection and prevention systems, and more particularly to a leak response shutoff kit comprising an overflow pan with a water sensor and an external water supply valve that integrates with an ice maker's controller to provide comprehensive leak protection beyond conventional internal monitoring systems.

BACKGROUND

Ice makers are common appliances in residential and commercial settings. Modern ice makers incorporate sophisticated water circulation systems, refrigeration components, and control mechanisms to automate the ice production process. These systems typically include internal monitoring capabilities such as drain alarms that detect pressure changes in drain lines and can identify issues like clogged passages or malfunctioning pump components. However, existing internal detection systems primarily focus on monitoring operational aspects of water circulation and drainage processes rather than detecting leaks that may occur at connection points, fittings, or other plumbing interfaces throughout the ice maker assembly. The majority of water leak incidents in ice makers stem from failures at plumbing connections and fittings, which can develop gradually due to thermal cycling, vibration, component aging, or installation issues. When such leaks occur, water may escape from the ice maker housing and accumulate in areas where internal detection systems cannot sense moisture presence, creating a gap in leak protection that can result in undetected water accumulation and property damage to flooring, cabinetry, and surrounding structures.

SUMMARY

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
In one embodiment, an ice maker assembly is provided. In this embodiment, the ice maker assembly comprises an ice maker including a cabinet, an ice formation device positioned in the cabinet, a water system positioned in the cabinet for delivering water to the ice formation device and draining water from the ice maker, a refrigeration system positioned in the cabinet for cooling the ice formation device, and a controller for controlling the refrigeration system and the water system to make ice using the ice formation device. The ice maker assembly further comprises an overflow pan positioned below the cabinet. The ice maker assembly also comprises a sensor positioned in the overflow pan for detecting water in the overflow pan, the sensor communicatively connected to the controller. The ice maker assembly additionally comprises an external water supply valve fluidly connected to the water system upstream of the ice maker and communicatively connected to the controller, wherein the controller is configured to actuate the external water supply valve to shut off water supply to the ice maker in response to the sensor detecting water in the overflow pan.
In other embodiments, the ice maker assembly may include one or more of the following features. The sensor may be a resistive sensor configured to detect water by measuring electrical resistance between sensor contacts. The cabinet may have a cabinet footprint and the overflow pan may have a pan footprint corresponding to the cabinet footprint. The cabinet may have a front-to-back cabinet span and the overflow pan may have a pan span in an inclusive range of from 80% to 100% of the cabinet span. The cabinet may have a cabinet width and the overflow pan may have a pan width in an inclusive range of from 90% to 100% of the cabinet width. The cabinet width may be 24 inches or less. The overflow pan may be configured to catch water leaking from any water system interface inside the ice maker. The overflow pan may comprise a pan bottom that slopes downward from front to back. The sensor may be positioned at a rear end portion of the overflow pan at a low point of the pan bottom. The overflow pan may have a pan height in an inclusive range of from 1 inch to 2 inches. The overflow pan may comprise a plurality of foot cavities configured to receive support feet of the cabinet. The water system may comprise an internal water inlet valve, the controller configured to shut off both the internal water inlet valve of the water system and the external water supply valve in response to the sensor detecting water in the overflow pan. The controller may be configured to generate an alarm signal and cease ice making operations in response to the sensor detecting water in the overflow pan.
In another embodiment, a leak response shutoff kit for an ice maker is provided. In this embodiment, the leak response shutoff kit comprises an overflow pan having a pan bottom with a peripheral wall extending upward therefrom. The leak response shutoff kit further comprises a leak sensor configured to detect water in the overflow pan, the leak sensor including a sensor cable terminated by a cable connector configured to connect to a controller of the ice maker. The leak response shutoff kit also comprises an external water supply valve including a valve housing containing a valve mechanism, the external water supply valve including an inlet fitting, an outlet fitting, a valve actuator, and a control circuit, the external water supply valve further including a control cable with a cable connector configured to connect to the controller of the ice maker.
In other embodiments, the leak response shutoff kit may include one or more of the following features. The leak sensor may be a resistive sensor configured to detect water by measuring electrical resistance between sensor contacts. The pan bottom may slope downward from a front portion to a rear portion, and the leak sensor may be positioned at the rear portion of the pan bottom. The overflow pan may further comprise a plurality of foot cavities forming depressions in the pan bottom. The external water supply valve may further comprise an indicator panel including one or more LED indicators for indicating valve status and an input device for user input to initiate reset and test functions.
In yet another embodiment, a method of operating an ice maker is provided. In this embodiment, the method comprises detecting water in an overflow pan positioned below the ice maker via a sensor positioned in the overflow pan. The method further comprises transmitting a signal from the sensor to a controller of the ice maker. The method also comprises issuing a control signal from the controller to an external water supply valve positioned upstream from the ice maker in response to receiving the signal from the sensor. The method additionally comprises actuating the external water supply valve to shut off water supply upstream of the ice maker such that no water is supplied to any portion of the ice maker.
In other embodiments, the method may include one or more of the following features. The method may further comprise a step of shutting off an internal water inlet valve of the ice maker simultaneously with actuating the external water supply valve. The method may further comprise a step of generating an alarm signal and ceasing ice making operations in response to detecting water in the overflow pan. The step of detecting water may comprise measuring electrical resistance between sensor contacts of a resistive sensor positioned at a rear portion of the overflow pan.
In yet another embodiment, a method of installing a leak response shutoff kit for an ice maker is provided. In this embodiment, the method comprises positioning an overflow pan below a cabinet of the ice maker such that the overflow pan is configured to catch water leaking from the ice maker. The method further comprises connecting a leak sensor positioned in the overflow pan to a controller of the ice maker via a cable connector. The method also comprises installing an external water supply valve in a water supply line upstream from the ice maker at a location external to a cabinet of the ice maker containing an ice formation device, a water system, and a refrigeration system of the ice maker. The method additionally comprises connecting the external water supply valve to the controller of the ice maker via a control cable such that the controller can actuate the external water supply valve to shut off water supply to the ice maker.
In other embodiments, the method may include one or more of the following features. The step of positioning the overflow pan may comprise positioning the overflow pan such that a plurality of foot cavities formed in a pan bottom of the overflow pan receive support feet of the cabinet. The step of connecting the leak sensor may comprise connecting a resistive sensor configured to detect water by measuring electrical resistance between sensor contacts positioned at a rear portion of the overflow pan.
The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.

BRIEF DESCRIPTION OF FIGURES

Non-limiting and non-exhaustive examples are described with reference to the following figures.

FIG. 1 is a schematic illustration of an ice maker assembly with an overflow pan and leak sensor, according to aspects of the present disclosure.

FIG. 2 is a schematic block diagram of a control system for the ice maker of FIG. 1 , according to aspects of the present disclosure.

FIG. 3 is a schematic illustration of a leak response shutoff kit for an ice maker, according to aspects of the present disclosure.

FIG. 4 is a plan view of the overflow pan of FIG. 3 showing dimensional relationships, according to aspects of the present disclosure.

Reference numerals in the drawings correspond to like elements in the detailed description. Such reference numerals are used to facilitate an understanding of the disclosure and are not intended to be limiting.

DETAILED DESCRIPTION

The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.
Water leaks in ice makers represent a substantial concern for property owners, particularly in residential and commercial settings where ice makers operate continuously and often without direct supervision. These leaks can originate from various sources within the ice making system, including water supply connections, internal plumbing fittings, valve assemblies, and drain components. When leaks occur, water may accumulate beneath and around the ice maker, potentially causing extensive damage to flooring, cabinetry, and surrounding structures. The financial impact of such water damage can be considerable, often exceeding the value of the ice maker itself and requiring costly repairs to restore affected areas.
Conventional ice makers typically incorporate internal leak detection systems that monitor specific aspects of the water circulation process. These systems can include drain alarms that detect pressure changes in drain lines and can identify issues such as clogged drain passages, pinched tubing, or malfunctioning pump components. While these internal detection mechanisms provide some protection against certain types of failures, they possess inherent limitations in their scope of coverage. The existing systems primarily focus on monitoring the operational aspects of the water circulation and drainage processes rather than detecting leaks that may occur at connection points, fittings, or other plumbing interfaces throughout the ice maker assembly.
The majority of water leak incidents in ice makers stem from failures at plumbing connections and fittings rather than from the operational components monitored by conventional internal systems. These connection-related leaks can develop gradually over time due to factors such as thermal cycling, vibration, component aging, or installation issues. When such leaks occur, water may escape from the ice maker housing and accumulate in areas where internal detection systems cannot sense the presence of moisture. This limitation creates a gap in leak protection that can result in undetected water accumulation and subsequent property damage.
As explained below, this disclosure provides a comprehensive leak response shutoff kit that addresses these limitations by providing external monitoring and control capabilities that integrate directly with the ice maker's existing controller to extend protection beyond the scope of internal ice maker systems. The kit incorporates an overflow pan positioned beneath the ice maker to capture any water that may leak from connections or fittings within the appliance. A sensor system monitors the overflow pan for the presence of water and communicates directly with the ice maker's controller through cable connections to initiate coordinated protective responses when leaks are detected. Additionally, the kit includes an external water supply valve that receives control signals from the ice maker's controller to shut off water flow upstream of the ice maker, enabling the controller to simultaneously manage both internal water inlet valves and the external supply valve for a more comprehensive approach to leak mitigation than internal systems alone can achieve.
The integration of external leak detection and water shutoff capabilities provides enhanced protection against property damage by addressing leak sources that may not be detectable through internal monitoring systems. This approach recognizes that effective leak protection requires monitoring of the entire ice maker installation rather than focusing solely on specific operational components. By combining overflow collection, external sensing, and upstream water control, the leak response shutoff kit offers a more comprehensive solution for protecting against the various types of water leaks that can occur in ice maker installations.
Referring to FIG. 1 , an example embodiment of an ice maker in accordance with the present disclosure is generally indicated at reference number 103. The ice maker 103 is configured as a residential appliance designed to produce ice in a compact form factor suitable for undercounter installation. Aspects of the present disclosure can also be used with other types of ice makers such as commercial all-in-one ice makers, or modular ice makers. The ice maker 103 includes a cabinet 105 that houses the various operational components and systems for ice production. An access door 106 is mounted on the cabinet 105 for opening and closing the cabinet to provide selective access to an ice bin 104 positioned within the cabinet 105 for ice storage and retrieval. The cabinet 105 is supported by a plurality of support feet 1051 that elevate the cabinet 105 above the installation surface and provide stability during operation. In some embodiments, the support feet 1051 are adjustable leveling feet that allow for proper positioning and alignment of the ice maker 103 during installation.
The cabinet 105 incorporates an insulating wall 107 that thermally separates different operational zones within the cabinet. The insulating wall 107 divides the interior space to define a warm space 108 that contains heat-generating components. The insulating wall 107 thermally isolates the warm space 108 from the cold space 109 in the cabinet 105, which contains the ice bin 104 and various chilled ice production components. This thermal separation enhances the efficiency of ice production by preventing heat transfer from operational components to the ice formation areas. Those skilled in the art will appreciate that the all-in-one residential ice maker form factor depicted schematically in FIG. 1 is space-constrained. To maximize ice storage and production capacity, all of the available volume inside the cabinet 105 is put to use for the ice making components. Typically, there is no excess space for auxiliary safety features like leak detection and water shutoff.
An ice formation device is positioned within the cabinet 105 to facilitate the conversion of liquid water into solid ice. In the illustrated embodiment, the ice formation device comprises a freeze plate 110 that is oriented horizontally within the cabinet 105. The freeze plate 110 defines a plurality of ice molds 111 that shape the water during the freezing process to produce ice pieces of predetermined dimensions and configurations. The ice molds 111 open downward to receive water that is directed upward from below the freeze plate 110. This configuration allows for the production of clear, hard ice by enabling impurities to be expelled from the water as the freezing process progresses from the bottom of each ice mold 111 upward.
A refrigeration system is positioned within the cabinet 105 to provide the cooling capacity for ice formation. In this embodiment, the refrigeration system is a compression-driven refrigeration system, but other types of cooling systems can also be used without departing from the scope of the disclosure. As shown in FIG. 1 , the refrigeration system includes a compressor 112 that circulates refrigerant through the system components. A heat exchanger 114 is configured to reject heat from the compressed refrigerant, and in certain embodiments, the heat exchanger 114 functions as a condenser for condensing refrigerant vapor. A condenser fan 115 is positioned to direct airflow across the heat exchanger 114 to enhance heat rejection efficiency. The refrigeration system further includes an expansion device 118 that reduces the temperature and pressure of the refrigerant before the refrigerant enters an evaporator 120. The evaporator 120 is positioned along or adjacent to the freeze plate 110 to extract heat from the water in the ice molds 111 during the freezing process.
The refrigeration system incorporates a hot gas valve 124 that provides selective control over the refrigerant flow path during different operational phases. During ice formation, the hot gas valve 124 remains closed to direct refrigerant through the normal cooling cycle via the heat exchanger 114 and expansion device 118. During ice harvesting operations, the hot gas valve 124 opens to direct warm refrigerant directly to the evaporator 120, thereby warming the freeze plate 110 to release formed ice pieces from the ice molds 111. This selective refrigerant routing enables the ice maker 103 to alternate between ice formation and ice harvesting phases as part of the overall ice production cycle.
A water system is positioned within the cabinet 105 for delivering water to the ice formation device and managing water flow throughout the ice maker 103. The water system includes a water sump 130 that collects and stores water for recirculation during ice formation cycles. A water pump 132 is fluidly connected to the water sump 130 to circulate water through the system. A water line 134 connects the water pump 132 to a distributor 146 that directs water spray S toward the freeze plate 110 and ice molds 111. The distributor 146 is positioned below the freeze plate 110 to spray water upward into the ice molds 111, where a portion of the water freezes while unfrozen water returns to the water sump 130 for continued circulation.
Accordingly, it can be seen that in the illustrated embodiment, the ice maker 103 is a vertical spray ice maker of the type which has a horizontally oriented freeze plate 110 that constitutes the ice formation device. The horizontal freeze plate 110 defines a plurality of ice molds 111 that open downward to receive water S sprayed upward from below. Those skilled in the art will recognize that this type of ice maker is used to make very hard, clear ice. Other types of ice makers such as batch ice makers with vertically oriented freeze plates are also contemplated to be in the scope of this disclosure. Batch ice makers with vertically oriented freeze plates differ from the illustrated ice maker in that the freeze plate extends in a generally vertical plane, with a water distributor above the vertical freeze plate so that water flows down the freeze plate during ice making cycles. Still other types of ice makers such as auger-driven flake or nugget ice makers can also be used, in which case the ice formation device includes a chilled cylindrical surface on which water forms as ice. Any suitable type of ice formation device can be used without departing from the scope of the disclosure.
With continued reference to FIG. 1 , the water system includes a supply line 138 that connects the ice maker 103 to an external water source W. An internal water inlet valve 140 controls the flow of water through the supply line 138 to regulate water entry into the water sump 130. The water inlet valve 140 is a prefabricated component of the ice maker 103, located within the interior of the cabinet 105. During ice production cycles, the water inlet valve 140 is periodically opened to fill the sump 130 to a predefined ice making water level, at which point the water inlet valve 140 is closed.
The water system further incorporates drainage components including a drain line 142 through which water can be drained from the sump 130. A drain valve 144 is connected between the water line 134 and the drain line 142 to selectively enable water removal from the water sump 130 when drainage operations are initiated. The drain valve 144 is normally positioned so that water pumped by the pump 132 is directed through the water line 134 to the sprayer 146. To drain the sump, the drain valve 144 is adjusted so the water pump 132 instead pumps water into the drain line 142. The illustrated ice maker also includes a passive overflow drain 141 that is configured to drain water through the drain line 142 if the water level in the sump ever exceeds a maximum level.
An ice chute 147 is positioned between the distributor 146 and the freeze plate 110 to guide harvested ice pieces toward the ice bin 104 while allowing water spray and drainage to pass through the ice chute 147. The ice chute 147 comprises a grill or porous structure that permits liquid flow while blocking solid ice pieces from falling back toward the distributor 146.
Referring to FIG. 2 , the ice maker 103 includes various sensors for monitoring operational conditions and system status. An ice level sensor 145 is configured to detect the accumulation of ice within the ice bin 104 and provide feedback to control ice production cycles. A water level sensor 136 monitors the water level within the water sump 130 to ensure adequate water supply for ice formation operations. As further shown in FIG. 2 , a harvest sensor 166 is configured to determine when ice harvesting operations have been completed and ice pieces have been successfully released from the ice molds 111.
Referring still to FIG. 2 , a controller 160 is provided to manage the operation of the refrigeration system and water system components. The controller 160 includes a processor 162 that executes control algorithms and processes input signals from various sensors and operational components. A memory component 164 stores control instructions, operational parameters, and data related to ice maker 103 performance. The processor 162 accesses the memory component 164 to retrieve stored instructions and data for controlling ice production cycles, system diagnostics, and response protocols. The processor 162 may be, for example, a commercially available microprocessor, an application-specific integrated circuit (ASIC) or a combination of ASICs, which are designed to achieve one or more specific functions, or enable one or more specific devices or applications. In certain embodiments, the controller 160 may be an analog or digital circuit, or a combination of multiple circuits. The controller 160 may also include one or more memory components 164 for storing data in a form retrievable by the controller. The controller 160 can store data in or retrieve data from the one or more memory components 164.
The controller 160 receives input signals from multiple sensors including the water level sensor 136, the harvest sensor 166, and the ice level sensor 145 to monitor system conditions and operational status. Based on these input signals and stored control algorithms, the controller 160 generates output control signals to manage various system components. The controller 160 controls refrigeration system components including the compressor 112, the condenser fan 115, the expansion device 118, and the hot gas valve 124 to regulate the chilling and harvest phases of ice production cycles. The controller 160 also manages water system components including the water pump 132, the internal water inlet valve 140, and the drain valve 144 to control water circulation, filling, and drainage operations.
A user interface 165 is connected to the controller 160 to enable user interaction with the ice maker 103. The user interface 165 includes input devices such as buttons, switches, or touch-sensitive controls that allow users to initiate operations, adjust settings, or acknowledge system alerts. The user interface 165 also includes display elements such as indicator lights, digital displays, or status panels that provide information about ice maker 103 operation, system status, or alert conditions. Through the user interface 165, users can monitor ice production progress, receive notifications of maintenance requirements, or respond to system alerts that require user intervention.
During an ice batch production cycle, controller 160 controls the refrigeration system to chill the freeze plate 110 and simultaneously controls the pump 132 to pump water through the water line 134 and through the distributor 146. The liquid S is sprayed upward past the chute 147 into the molds 111 of the freeze plate 110. Some of the water freezes in the molds 111 and unfrozen liquid water falls off of the freeze plate 110, past the chute 147 and the sprayer 146, into the sump 130 where it can be recirculated by the water pump 132. This water cycle continues to progressively chill the liquid water that is recirculating until a sufficient amount of the water freezes as ice in the molds 111. At that point, the controller turns off the water pump 132 and opens the hot gas valve 124 to heat the freeze plate 110, melting the ice I until it demolds, falls onto the chute 147, and slides off the chute into the ice bin 104.
Referring to FIG. 3 , a leak response shutoff kit 200 is configured to provide comprehensive leak protection for the ice maker 103 by monitoring for water accumulation and controlling water supply upstream of the ice maker 103 at a location altogether external to the ice maker cabinet 105. In general, the leak response shutoff kit 200 comprises an overflow pan 210 configured to be positioned below the cabinet 105 (see FIG. 1 ), a leak sensor 220 configured to detect water in the overflow pan 210, and an external water supply valve 240 fluidly connected to the water system upstream of the ice maker 103. The leak response shutoff kit 200 integrates with the existing controller 160 of the ice maker 103 to provide coordinated leak detection and water shutoff capabilities that extend beyond the scope of internal monitoring systems. The illustrated leak response shutoff kit 200 addresses the limitations of conventional internal leak response systems by providing external monitoring and control that can detect leaks from any water system interface within the ice maker 103, including connection points, fittings, and plumbing interfaces that internal systems cannot monitor.
The overflow pan 210 comprises a pan bottom 212 with a peripheral wall 214 (e.g., a rim) extending upward therefrom to define a water collection area beneath the cabinet 105. In the illustrated embodiment, the pan bottom 212 slopes downward from a front portion to a rear portion to direct any collected water toward a low point where detection can occur with minimal water accumulation. The peripheral wall 214 extends upward from the perimeter of the pan bottom 212 to contain water that leaks from the ice maker 103 and prevent water from spreading beyond the overflow pan 210. The overflow pan 210 includes a plurality of foot cavities 216 that form depressions in the pan bottom 212 and are configured to receive the support feet 1051 of the cabinet 105. The foot cavities 216 allow the cabinet 105 to sit level within the overflow pan 210 despite the sloping pan bottom 212.
Referring to FIG. 4 , the overflow pan 210 is configured with dimensional relationships that correspond to the cabinet footprint CF (indicated by dotted line) of the cabinet 105. The cabinet 105 has a cabinet span CS measured from front to back, and the overflow pan 210 has a pan span PS in an inclusive range of from about 80% to about 100% of the cabinet span CS. Similarly, the cabinet 105 has a cabinet width CW, and the overflow pan 210 has a pan width PW in an inclusive range of from about 90% to about 100% of the cabinet width CW. In some embodiments, the cabinet width CW is 24 inches or less to accommodate undercounter installation requirements. The overflow pan 210 has a pan height PH (shown in FIG. 1 ) in an inclusive range of from about 1 inch to about 2 inches to provide adequate water collection capacity while maintaining a low profile beneath the cabinet 105. The overflow pan 210 is configured to catch water leaking from any water system interface inside the ice maker 103, including supply connections, internal plumbing fittings, valve assemblies, and drain components that are not monitored by internal detection systems.
Referring again to FIG. 3 , the leak sensor 220 is positioned at the rear portion of the overflow pan 210. In one or more embodiments, the leak sensor 220 is positioned on the pan bottom 212 at its low point. In the illustrated example, the leak sensor 220 is configured to mount at a location within a rear sensor span SS of the overflow pan 210, where the dimension of the sensor span SS is in an inclusive range of from 1 inch to 3 inches. The sensor 220 is configured to mount between the two rear foot cavities 216 in the illustrated embodiment. Positioning the leak sensor 220 at about the low point of the sloped pan bottom 212 ensures that even small amounts of leaked water will flow to and accumulate at the sensor location, enabling rapid detection and immediate system response to minimize potential water damage. In certain embodiments, the leak sensor 220 and overflow pan 210 can be factory-assembled with the leak sensor fixedly mounted on the pan bottom 212. In other embodiments, the kit 200 comes with the leak sensor 220 and the overflow pan 210 separated for field-installation.
In the illustrated embodiment, the leak sensor 220 is a resistive sensor configured to detect water by measuring electrical resistance between sensor contacts when water is present in the overflow pan 210. The sloping configuration of the pan bottom 212 may direct any leaking water to flow downward toward the leak sensor 220 location, enabling quick detection and response to water accumulation. The resistive sensor configuration provides several advantages for water detection in the overflow pan 210. Resistive sensors may offer reliable detection capabilities with relatively simple circuitry that can interface directly with the existing controller 160 without requiring complex signal processing or conditioning circuits. In some aspects, resistive sensors can provide immediate response to water presence, as the electrical resistance changes substantially when water bridges the sensor contacts, enabling rapid detection and system response. The resistive sensor design may be particularly suitable for the overflow pan 210 environment because it can detect even small amounts of water accumulation at the low point of the pan bottom 212. In some cases, resistive sensors can operate effectively with various water conditions, including water with different mineral contents or ionic concentrations that may be encountered in different geographic locations or water supply systems. Notably, a resistive sensor can even detect water that has been filtered by a reverse osmosis filter system. The sensor also functions reliably across a range of water temperatures that could occur during ice maker operation. Additionally, resistive sensors may provide cost-effective leak detection compared to more complex sensing technologies such as optical sensors or ultrasonic sensors. The simplicity of the resistive sensor design can contribute to system reliability by reducing the number of components that could potentially fail. In some embodiments, the resistive sensor configuration allows for straightforward calibration and testing procedures, enabling users or service technicians to verify proper sensor operation during installation or maintenance activities. The electrical characteristics of the resistive sensor may also provide compatibility with standard control system interfaces commonly found in ice maker controllers 160, facilitating integration without requiring specialized input circuits or signal conversion components. In some aspects, the resistive sensor can maintain consistent performance over extended periods of operation while requiring minimal maintenance or recalibration.
While one example embodiment uses a resistive water sensor for the leak sensor 220, it will be understood that any sensor capable of quickly detecting the presence of water in the overflow pan 210 can be used without departing from the scope of the disclosure. In one or more embodiments, the leak sensor 220 operates as a conductivity-based sensor that measures electrical conductivity between sensor contacts to detect water presence.
In the illustrated embodiment, a sensor cable 222 extends from the leak sensor 220 and terminates in a cable connector 224. The sensor cable 222 and cable connector 224 are configured to connect the leak sensor 220 to the controller 160 of the ice maker 103. In certain embodiments, the cable connector 224 facilitates plug-in connection between the leak sensor 220 and the controller 160 to transmit detection signals when water is present in the overflow pan 210.
In one example embodiment, the leak sensor 220 operates with electrical parameters including a working voltage in an inclusive range of from about 5 VDC to about 24 VDC, a maximum voltage of about 24 VDC, a maximum working current of about 0.5 Amp, and a temperature range in an inclusive range of from about 14° F. to about 150° F. The example leak sensor 220 described in this paragraph behaves as an open circuit when no water is present and behaves as approximately a 1.4 MΩ resistor when water is present, with the resistance varying based on water ionic content. In this example, the leak sensor 220 has dimensional specifications of approximately 3-10 cm length, 0.5-5 cm width, and 0.5-5 cm height and is housed in white ABS material.
Referring again to FIG. 1 , the leak response shutoff kit 200 includes an external water supply valve 240 that provides upstream water control capability by shutting off the water supply to the ice maker 103 at a location entirely remote from the ice maker cabinet 105. This external positioning represents a fundamental advantage over internal leak detection systems, as the external water supply valve 240 can completely isolate the ice maker 103 from its water source W regardless of the specific location or nature of the leak within the ice maker. In typical residential installations, the ice maker 103 is positioned in one cabinet bay of a kitchen cabinet run while the external water supply valve 240 is installed in a completely separate cabinet bay, often in an undersink cabinet where water supply connections are readily accessible for installation and maintenance. This remote installation configuration enables the external water supply valve 240 to provide comprehensive water shutoff protection even in situations where internal ice maker components may be compromised or inaccessible. The external water supply valve 240 is fluidly connected upstream in the water supply path between the external water source W and the internal supply line 138, ensuring that when activated, no water can reach any portion of the ice maker's internal water system, thereby providing complete protection against continued water flow during leak conditions.
Referring to FIG. 2 , despite being an external accessory, the external water supply valve 240 is configured to interface directly with the ice maker controller 160, e.g., the same control circuit that directs ice production and harvest. This direct integration enables the controller 160 to coordinate the operation of both internal and external water control components as part of a unified leak response system. The external water supply valve 240 included in the leak response kit 200 serves a fundamentally different function from the internal water inlet valve 140 in the prefabricated ice maker. Whereas the internal water inlet valve 140 operates during normal ice production cycles to periodically open and fill the sump 130 to a predefined ice making water level before closing again, the external water supply valve 240 remains in a standby (open) state during normal operations and is specifically designed to provide emergency water shutoff capability when leak conditions are detected. When activated by the ice maker's own controller 160 in response to leak detection signals, the external water supply valve 240 completely isolates the entire ice maker 103 from its water source, providing comprehensive protection that extends beyond the localized control that could be offered by the internal water inlet valve 140. This coordinated control architecture allows the controller 160 to simultaneously manage both the internal water inlet valve 140 and the external water supply valve 240, ensuring that water flow is terminated at multiple points in the supply chain to maximize leak protection effectiveness.
Referring to FIG. 3 , one example embodiment of the external water supply valve 240 will now be described. The external water supply valve 240 includes a valve housing 242 containing a valve mechanism 244 (shown schematically) that controls water flow through the supply valve 240. A valve actuator 246 is configured to operate the valve mechanism 244 to open and close the water flow path through the supply valve 240. In the illustrated embodiment, the valve actuator 246 comprises a solenoid actuator that receives electrical control signals to actuate the valve mechanism 244. The supply valve 240 includes a control circuit 248 that processes control signals from the controller 160 and manages the operation of the valve actuator 246.
The illustrated external water supply valve 240 further includes an inlet fitting 250 and an outlet fitting 252 supported on the valve housing 242. The inlet fitting 250 is generally configured for connecting the external water supply valve 240 to the water supply W, and the outlet fitting 252 is generally configured for connecting the supply valve to one end of tubing whose opposite end is connected to the water inlet of the ice maker 103. Various fittings suitable for connecting the external water supply valve 240 to suitable water supply tubing can be used for the inlet fitting 250 and the outlet fitting 252 without departing from the scope of the disclosure. The illustrated supply valve 240 also includes an integrated manual shutoff valve 254 that provides manual override capability for water shutoff independent of the electrical control system.
The external water supply valve 240 further includes a control cable 260 with a cable connector 262 configured to connect to the controller 160 of the ice maker 103 to enable communication between the supply valve 240 and the controller 160. A power cable 264 with a power connector 266 provides electrical power to the supply valve 240 for operation of the valve actuator 246 and control circuit 248. While the illustrated example uses separate cables for power and control signals, it will be understood that the external water supply valve could alternatively be configured to receive power and control signals over the same cable.
In the illustrated example, the external water supply valve 240 further comprises a status indicator 256 that includes one or more LED indicators for indicating valve status, including open, closed, and fault conditions. Optionally, the external water supply valve 240 can further include an input device 258 that enables user input capability to initiate reset and test functions for the supply valve 240.
In the illustrated embodiment, the supply valve 240 is configured as a normally open valve that remains open during normal ice maker operation to allow continuous water supply to the ice maker 103. When leak conditions are detected by the leak sensor 220, the controller 160 actively closes the external water supply valve 240 to shut off water flow upstream of the ice maker. In one or more embodiments, the controller 160 is configured to shut off both the internal water inlet valve 140 of the water system and the external water supply valve 240 simultaneously in response to the leak sensor 220 detecting water in the overflow pan 210. The supply valve 240 can be mounted beneath a sink adjacent to existing water supply fittings for convenient installation and accessibility. The controller 160 is configured to generate an alarm signal and cease ice making operations in response to the leak sensor 220 detecting water in the overflow pan 210, providing comprehensive leak response that includes water shutoff, operational cessation, and user notification.
The integrated design of the leak response shutoff kit 200 provides comprehensive leak protection by combining overflow collection through the overflow pan 210, sensitive detection through the leak sensor 220, and upstream water control through the supply valve 240 to address leak sources that conventional internal monitoring systems cannot detect.
An example method of installing the leak response shutoff kit 200 will now be described. The method of installing a leak response shutoff kit for an ice maker 103 broadly comprises positioning an overflow pan 210 below a cabinet 105 of the ice maker, connecting a leak sensor 220 to a controller 160 of the ice maker, installing an external water supply valve 240 upstream from the ice maker, and establishing communication between the components. If the leak sensor is not preinstalled in the overflow pan, the installer may begin by installing the leak sensor at the low point of the pan bottom 212, e.g., at a suitable location within the sensor span SS. With the leak sensor properly installed in the overflow pan, the installer can position the overflow pan such that the overflow pan is configured to catch water leaking from the ice maker. In the illustrated embodiment, the step of positioning the overflow pan comprises positioning the overflow pan such that a plurality of foot cavities 216 formed in a pan bottom of the overflow pan receive support feet 1051 of the cabinet. The installer aligns the foot cavities with the support feet and lowers the cabinet onto the overflow pan, allowing the support feet to settle into the foot cavities for stable positioning. The installer verifies that the overflow pan extends beneath the water system connections and plumbing interfaces within the cabinet to provide comprehensive leak collection coverage.
The installer connects the leak sensor 220 positioned in the overflow pan 210 to a controller 160 of the ice maker 103 via a cable connector 224 to establish communication between the leak sensor and the existing control system. In the illustrated embodiment, the step of connecting the leak sensor 220 comprises connecting a resistive sensor configured to detect water by measuring electrical resistance between sensor contacts positioned at a rear portion of the overflow pan. The installer routes the sensor cable 222 from the leak sensor location to the controller and engages the cable connector 224 with a corresponding input port of the ice maker 103. In one embodiment, the installer verifies proper connection by testing the sensor response and confirming that the controller receives detection signals when water contacts the sensor elements.
The installer installs the external water supply valve 240 in a water supply line upstream from the ice maker 103 at a location external to a cabinet 105 of the ice maker containing an ice formation device, a water system, and a refrigeration system of the ice maker. The installer identifies a suitable installation location in the water supply path, typically in an undersink cabinet or utility area where water supply connections are accessible. The installer shuts off the water supply, cuts the supply line at the selected location, and installs the external water supply valve using appropriate fittings to connect the inlet fitting 250 and outlet fitting 252 to the water supply tubing. In addition to making the fluid connections, the installer also connects the external water supply valve to the controller 160 of the ice maker via the control cable 260 such that the controller can actuate the external water supply valve to shut off water supply to the ice maker. The installer routes the control cable from the external water supply valve to the controller and connects the cable connector 262 to establish communication for coordinated leak response operations. The installer also connects the power cable 264 to an appropriate power source via the power connector 266 to provide electrical power to the valve actuator 246 and control circuit 248 for proper operation of the external water supply valve.
After the kit 200 has been installed it operates continuously to identify leaks that occur anywhere within the footprint CF of the ice maker and responds to them effectively immediately to prevent any water from spilling out of containment where it can cause property damage. If a leak does occur anywhere within the ice maker 103, the leaking water will collect in the overflow pan 210 and flow down the sloping pan bottom 212 to the low point where the leak sensor 220 encounters the water. In the illustrated embodiment, the leak sensor 220 continuously measures the electrical resistance between its sensor contacts. When water accumulates in the overflow pan 210 and contacts the leak sensor 220, the electrical resistance between the sensor contacts changes substantially from an open circuit condition to a measurable resistance value. The leak sensor 220 immediately transmits this detection signal through the sensor cable 222 and cable connector 224 to the controller 160, which processes the signal and recognizes the presence of a leak condition. In one embodiment, the controller 160 responds by simultaneously issuing control signals to both the internal water inlet valve 140 and the external water supply valve 240 to terminate water flow at multiple points in the supply chain.
The coordinated shutoff sequence ensures that water supply is interrupted both at the external supply valve 240 upstream of the ice maker 103 and at the internal water inlet valve 140 within the ice maker water system. In certain embodiments, the controller 160 also generates an alarm signal and ceases ice making operations in response to detecting water in the overflow pan. The controller 160 activates the user interface 165 to provide visual and audible notifications of the leak condition, alerting users to the detected water accumulation and the automatic protective response. In certain embodiments, the alarm can include a network-based notification that pushes the indication directly to the user via email or SMS messaging. The controller 160 simultaneously halts all ice production operations, including stopping the compressor 112, water pump 132, and other operational components to prevent additional water from entering the system during the leak condition. This comprehensive response sequence provides immediate protection against continued water accumulation while notifying users of the condition and the automatic protective measures that have been implemented.
The leak response shutoff kit provides comprehensive leak protection advantages over conventional internal monitoring systems by addressing water leaks from any source within the ice maker assembly, including connection points, fittings, and plumbing interfaces that internal systems cannot detect. The kit enables automatic coordinated response through direct integration with existing ice maker controllers, allowing simultaneous control of both internal and external water shutoff valves to terminate water supply at multiple points in the supply chain when leak conditions are detected. The external positioning of the water supply valve provides complete isolation capability regardless of the specific location or nature of leaks within the ice maker, while the overflow pan configuration ensures containment and detection of leaked water before the water can spread beyond the ice maker footprint to cause property damage. The sloped pan bottom design directs any leaked water from anywhere within the pan footprint to flow downward toward the low point where the leak sensor is positioned, enabling faster detection and quicker system response times compared to flat pan configurations. The foot cavities formed in the pan bottom allow the ice maker to sit level and stable despite the sloped bottom configuration, ensuring proper ice maker operation while maintaining the drainage advantages of the sloped design. The resistive sensor configuration provides reliable water detection with simple circuitry that interfaces directly with existing ice maker controllers while maintaining consistent performance across various water conditions and temperatures. The integrated design combines sensitive water detection, immediate system response, complete isolation of the ice maker from the water supply, and user notification to provide enhanced safety features that extend protection beyond the scope of internal ice maker systems alone, thereby reducing the risk of costly water damage to flooring, cabinetry, and surrounding structures in residential and commercial installations.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

Claims

1. An ice maker assembly, comprising:

an ice maker including a cabinet, an ice formation device positioned in the cabinet, a water system positioned in the cabinet for delivering water to the ice formation device and draining water from the ice maker, a refrigeration system positioned in the cabinet for cooling the ice formation device, and a controller for controlling the refrigeration system and the water system to make ice using the ice formation device;

an overflow pan positioned below the cabinet;

a sensor positioned in the overflow pan for detecting water in the overflow pan, the sensor communicatively connected to the controller; and

an external water supply valve fluidly connected to the water system upstream of the ice maker and communicatively connected to the controller, wherein the controller is configured to actuate the external water supply valve to shut off water supply to the ice maker in response to the sensor detecting water in the overflow pan.

2. The ice maker assembly of claim 1, wherein the sensor is a resistive sensor configured to detect water by measuring electrical resistance between sensor contacts.

3. The ice maker assembly of claim 1, wherein the cabinet has a cabinet footprint and the overflow pan has a pan footprint corresponding to the cabinet footprint.

4. The ice maker assembly of claim 3, wherein the cabinet has a front-to-back cabinet span and the overflow pan has a pan span in an inclusive range of from 80% to 100% of the cabinet span.

5. The ice maker assembly of claim 3, wherein the cabinet has a cabinet width and the overflow pan has a pan width in an inclusive range of from 90% to 100% of the cabinet width.

6. The ice maker assembly of claim 5, wherein the cabinet width is 24 inches or less.

7. The ice maker assembly of claim 1, wherein the overflow pan is configured to catch water leaking from any water system interface inside the ice maker.

8. The ice maker assembly of claim 1, wherein the overflow pan comprises a pan bottom that slopes downward from front to back.

9. The ice maker assembly of claim 8, wherein the sensor is positioned at a rear end portion of the overflow pan at a low point of the pan bottom.

10. The ice maker assembly of claim 1, wherein the overflow pan has a pan height in an inclusive range of from 1 inch to 2 inches.

11. The ice maker assembly of claim 1, wherein the overflow pan comprises a plurality of foot cavities configured to receive support feet of the cabinet.

12. The ice maker assembly of claim 1, wherein the water system comprises an internal water inlet valve, the controller configured to shut off both the internal water inlet valve of the water system and the external water supply valve in response to the sensor detecting water in the overflow pan.

13. The ice maker assembly of claim 12, wherein the controller is configured to generate an alarm signal and cease ice making operations in response to the sensor detecting water in the overflow pan.

14. A leak response shutoff kit for an ice maker, comprising:

an overflow pan having a pan bottom with a peripheral wall extending upward therefrom;

a leak sensor configured to detect water in the overflow pan, the leak sensor including a sensor cable terminated by a cable connector configured to connect to a controller of the ice maker; and

an external water supply valve including a valve housing containing a valve mechanism, the external water supply valve including an inlet fitting, an outlet fitting, a valve actuator, and a control circuit, the external water supply valve further including a control cable with a cable connector configured to connect to the controller of the ice maker.

15. The leak response shutoff kit of claim 14, wherein the leak sensor is a resistive sensor configured to detect water by measuring electrical resistance between sensor contacts.

16. The leak response shutoff kit of claim 14, wherein the pan bottom slopes downward from a front portion to a rear portion, and the leak sensor is positioned at the rear portion of the pan bottom.

17. The leak response shutoff kit of claim 14, wherein the overflow pan further comprises a plurality of foot cavities forming depressions in the pan bottom.

18. The leak response shutoff kit of claim 14, wherein the external water supply valve further comprises an indicator panel including one or more LED indicators for indicating valve status and an input device for user input to initiate reset and test functions.

19. A method of operating an ice maker, the method comprising:

detecting water in an overflow pan positioned below the ice maker via a sensor positioned in the overflow pan;

transmitting a signal from the sensor to a controller of the ice maker;

issuing a control signal from the controller to an external water supply valve positioned upstream from the ice maker in response to receiving the signal from the sensor; and

actuating the external water supply valve to shut off water supply upstream of the ice maker such that no water is supplied to any portion of the ice maker.

20. The method of claim 19, further comprising a step of shutting off an internal water inlet valve of the ice maker simultaneously with actuating the external water supply valve.

21. The method of claim 20, further comprising a step of generating an alarm signal and ceasing ice making operations in response to detecting water in the overflow pan.

22. The method of claim 19, wherein the step of detecting water comprises measuring electrical resistance between sensor contacts of a resistive sensor positioned at a rear portion of the overflow pan.

23. A method of installing a leak response shutoff kit for an ice maker, the method comprising:

positioning an overflow pan below a cabinet of the ice maker such that the overflow pan is configured to catch water leaking from the ice maker;

connecting a leak sensor positioned in the overflow pan to a controller of the ice maker via a cable connector;

installing an external water supply valve in a water supply line upstream from the ice maker at a location external to a cabinet of the ice maker containing an ice formation device, a water system, and a refrigeration system of the ice maker; and

connecting the external water supply valve to the controller of the ice maker via a control cable such that the controller can actuate the external water supply valve to shut off water supply to the ice maker.

24. The method of claim 23, wherein the step of positioning the overflow pan comprises positioning the overflow pan such that a plurality of foot cavities formed in a pan bottom of the overflow pan receive support feet of the cabinet.

25. The method of claim 24, wherein the step of connecting the leak sensor comprises connecting a resistive sensor configured to detect water by measuring electrical resistance between sensor contacts positioned at a rear portion of the overflow pan.