Cold Plate Defrosting System Using Sensor-Activated Heating Element
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Solution Overview
Problem
Phase-change material (PCM) cold plates used in refrigerated compartments are susceptible to frost and ice accumulation, which inhibits their ability to absorb heat effectively, requiring manual defrosting that is time-consuming and inconvenient, and can lead to temperature increases that may spoil perishable products.
Innovation Solution
A defrosting system with a sensor to detect frost on the cold plate and a heating element, such as a foil heating element, affixed to the cold plate, which is activated by a control unit to melt frost without significantly increasing the interior volume temperature, using a method that includes activating the heating element for a predetermined time or until a temperature maximum is reached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual defrosting is performed, then frost is removed from the cold plate, but the cooler must be taken offline and temperature increases occur that may spoil perishable products
Solution Approach 1:
The defrosting system automatically detects frost accumulation using a sensor and activates the heating element without human intervention. The system monitors the cold plate surface temperature and controls the heating element to melt frost while maintaining the cooler online, eliminating the need for manual defrosting operations.
Solution Approach 2:
The system uses a temperature sensor to continuously monitor the cold plate surface temperature and provides feedback to the control unit. Based on this feedback, the control unit adjusts the heating element operation to achieve optimal defrosting while preventing excessive temperature rise that would spoil perishable products.
2Reliability
If a heating element is applied to melt frost, then frost removal effectiveness is improved, but the risk of significantly increasing interior volume temperature increases
Solution Approach 1:
The heating element is applied locally to the cold plate surface where frost accumulates, rather than heating the entire interior volume. This localized heating approach efficiently melts frost on the cold plate while minimizing heat transfer to the perishable products and maintaining the overall interior temperature stable.
Solution Approach 2:
The defrosting system operates continuously or periodically based on sensor detection, maintaining the cold plate's heat absorption capability without interrupting the cooling function. The heating element is activated only when frost is detected and deactivated when the cold plate surface reaches a predetermined temperature, ensuring continuous optimal performance.
3Reliability
If the heating element is activated for extended periods, then complete frost removal is achieved, but energy consumption and temperature rise increase
Solution Approach 1:
The heating element is activated periodically based on frost detection rather than continuously. The control unit monitors the cold plate surface temperature and activates the heating element only when frost is detected, deactivating it when the predetermined temperature is reached or after a set time period, thereby reducing unnecessary energy consumption.
Solution Approach 2:
The system uses partial action by activating the heating element only to the extent needed to melt the detected frost layer. The heating element operates at controlled power levels and for limited time periods based on sensor feedback, achieving sufficient frost removal without excessive energy input that would cause unnecessary temperature rise.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively removes frost from the cold plate without taking the cooler offline or significantly raising the interior temperature, ensuring the cold plate functions optimally and maintains the desired storage temperature for perishable products.
Implementation Method 1
a heating element affixed to the surface of the cold plate configured to at least partially melt frost on the cold plate
Implementation Method 2
the PCM is able to absorb heat while maintaining a constant temperature
Implementation Method 3
phase-change material (PCM) cold plates are commonly used to absorb heat
Data Source
AI summary
A cooler including a cabinet defining an interior volume for storing a perishable product. A cold plate is disposed within the cabinet, and the cold plate is configured to absorb heat within the cabinet. The cooler further includes a defrosting system that includes a sensor configured to detect a presence of frost on a surface of the cold plate, a heating element affixed to the surface of the cold plate that is configured to at least partially melt frost on the cold plate, and a control unit configured to selectively activate and deactivate the heating element when the presence of frost is determined by the sensor.