Harness free ice maker system
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Solution Overview
Problem
Existing ice makers in refrigerators require a wiring harness to pass through the freezer compartment wall for power and control, which is costly, cumbersome, and poses safety risks due to potential water exposure and connector disconnection.
Innovation Solution
An ice maker system utilizing magnetic power transfer through primary and secondary coils, eliminating the need for a wiring harness by delivering power and control signals wirelessly across the freezer compartment wall, with a secondary coil sealed within the housing and a primary coil outside, enabling inductive coupling for power and data communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wiring harness is used to pass through the freezer compartment wall for power and control, then electrical power and control signals can be delivered to the ice maker, but the installation becomes costly and cumbersome, and safety risks increase due to potential water exposure and connector disconnection
Solution Approach 1:
The patent replaces the mechanical wiring harness system with an electromagnetic induction system. A primary coil mounted on the exterior of the freezer wall and a secondary coil inside the freezer compartment create a magnetic coupling that transfers both power and control signals without physical wire penetration. This eliminates connectors, sealing requirements, and exposure risks while maintaining reliable electrical connection.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary medium to transfer energy and control signals between the primary coil (exterior) and secondary coil (interior). This magnetic coupling acts as a mediator that allows electrical communication without direct physical connection, solving the problem of wire penetration through the insulated wall while maintaining safety and reliability.
2Ease of manufacture
If a wiring harness passes through the freezer wall, then power and control are provided, but manufacturing complexity increases due to sealing requirements and adhesive application to prevent moisture ingress
Solution Approach 1:
The patent eliminates the mechanical sealing process entirely by replacing the wiring harness penetration method with electromagnetic induction. The primary and secondary coils are mounted on opposite sides of the insulated wall without requiring any holes, seals, or adhesives, dramatically simplifying both manufacturing and assembly processes.
Solution Approach 2:
The patent extracts the wiring harness and its associated sealing components from the system. By removing the need for physical wire penetration, the complex sealing process involving gaskets and adhesives is completely eliminated, leaving only the simple coil mounting operations.
3Reliability
If connectors are used for the wiring harness, then electrical connection is established, but safety hazards increase due to potential water spill contact and accidental disconnection
Solution Approach 1:
The patent replaces the mechanical connector system with an electromagnetic field-based connection. The magnetic coupling between primary and secondary coils maintains stable electrical connection without any physical connectors that could be exposed to water or accidentally disconnected, eliminating the safety hazards entirely.
Solution Approach 2:
The magnetic field serves as an intermediary that transfers electrical energy and control signals without requiring direct physical contact between conductors. This eliminates the exposure risk to water while maintaining reliable power and control delivery to the ice maker.
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
Simplifies installation, enhances safety by reducing electrical hazards, and improves assembly efficiency while maintaining reliable power and control operations.
Implementation Method 1
A secondary coil is supported by the housing on the sidewall to receive electrical energy from an oscillating magnetic field passing through the freezer cabinet wall
Implementation Method 2
An oscillating magnetic field passing through the freezer cabinet wall delivers power and control signals to a secondary coil inside the motor unit housing
Data Source
Figure 1
Figure 2
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AI summary
An ice maker (10) allows for installation without the need for electrical harnesses by employing closely adjacent secondary (36) and primary (42) coils that communicate electrical energy through an oscillating magnetic field through the freezer wall (26). A data signal may be superimposed on the electrical energy to allow the ice maker (10) to control a valve (90) outside of the freezer cabinet.