Ice Maker Overflow Control During Cutter Grid Ice Release
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Solution Overview
Problem
Existing ice makers face issues with excess water overflow during the ice cutting process, which can create discomfort and product dissatisfaction by dripping onto user-accessible areas and electronics.
Innovation Solution
An ice making apparatus with a control unit that calculates the water flow rate and valve open time to manage water supply, includes a contact sensor, recirculation pump, and fluid diverter to divert excess water away from user-accessible areas, and features a thermistor for temperature-controlled ice production and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If gravity is used to feed ice into a container, then ice can be easily extracted by the user, but excess water overflows and creates discomfort and product dissatisfaction
Solution Approach 1:
The patent extracts the harmful byproduct water from the ice feeding path by introducing a separate water evacuation system. The water evacuation conduit removes excess water from the ice container, separating the ice gravity-feeding function from the water management function, thereby preventing water overflow while maintaining easy ice extraction.
Solution Approach 2:
The patent introduces an intermediary water evacuation system (conduit and sump) between the ice container and the environment. This intermediary structure captures and redirects excess water away from user-accessible areas, mediating between the gravity-fed ice flow and the need to prevent water overflow.
2Productivity
If water supply is increased for consistent ice output, then ice production efficiency improves, but water overflow increases and reaches user-accessible areas
Solution Approach 1:
The patent implements a feedback mechanism using a contact sensor that detects water level in the reservoir. When the sensor detects excess water, it signals the control unit to close the water inlet valve, creating a closed-loop feedback system that automatically regulates water supply to prevent overflow while maintaining consistent ice production.
Solution Approach 2:
The patent dynamically changes the water supply parameter (valve open time) based on calculated flow rate. The control unit calculates the actual flow rate and adjusts the valve open time accordingly, optimizing water supply parameters to achieve consistent ice output without causing water overflow.
3Stability of the object's composition
If valve open time is extended to ensure adequate water supply, then ice production consistency improves, but water overflow increases
Solution Approach 1:
The patent dynamically adjusts the valve open time parameter based on calculated flow rate measurements. By changing this parameter in real-time based on actual water delivery conditions, the system ensures adequate water supply for consistent ice production while preventing excessive water accumulation that would cause overflow.
Solution Approach 2:
The patent replaces fixed mechanical timing mechanisms with a control system that calculates and adjusts valve open time based on measured flow rate. This substitution of mechanical timing with calculated control allows precise water supply management that maintains ice production consistency without generating excess water.
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 solution effectively manages water overflow, ensuring consistent ice output and preventing water from reaching user-accessible areas, while maintaining efficient ice production and storage.
Implementation Method 1
A contact sensor may be disposed within the reservoir
Implementation Method 2
the recirculation pump may transport water from the reservoir through a distributor, and onto an evaporator plate
Implementation Method 3
onto an evaporator plate cooled to a temperature below the freezing point of the desired fluid to be frozen
Implementation Method 4
an evaporator plate cooled to a temperature below the freezing point of the desired fluid to be frozen
Implementation Method 5
a thermistor may be provided at a predetermined height within the storage element and in electrical communication with the control unit. The thermistor may be configured to measure the temperature at the predetermined height
Implementation Method 6
a fluid diverter may be disposed adjacent the cutter grid and may be configured to collect a fluid byproduct or meltwater from the cutter grid and divert it toward at least one side of an ice storage element
Data Source
AI summary
A stand alone ice making appliance or an ice maker within an appliance is provided including a fluid supply inlet, a fluid reservoir that is configured to receive a fluid from the fluid supply inlet, a cooling plate that is in fluid communication with the fluid reservoir, a refrigeration device in thermal contact with the cooling plate that is configured to freeze a predetermined amount of fluid to form a section of ice, a cutter grid configured adjacent the cooling plate to divide the section of ice, wherein at least a portion of the ice produces an excess fluid, an ice storage area in communication with the cutter grid where the storage area has at least one vertical wall, and a fluid diverter configured adjacent the cutter grid that is configured to direct the excess fluid toward the at least one vertical wall.