Ice maker for a refrigerator and method for synchronizing an implementation of an ice making cycle and an implementation of a defrost cycle of an evaporator in a refrigerator
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Solution Overview
Problem
Conventional ice makers in refrigerators face inefficiencies due to airflow obstruction and vortex formation, which affects the entire ice tray's cooling and delays ice harvesting, while defrost cycles interfere with ice production, requiring additional time and energy to cool components.
Innovation Solution
The ice maker design features an air handler with an outlet diffuser and fan configuration that directs airflow linearly to ensure complete ice tray cooling, and a method to synchronize ice making and defrost cycles to prevent overlap, allowing for efficient ice production by delaying or advancing defrost operations based on the ice making cycle phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional fan configuration is used to direct airflow toward the ice tray, then the fan can provide cooling, but airflow obstruction and vortex formation occur which prevents complete ice tray cooling
Solution Approach 1:
The outlet diffuser is segmented into multiple radial sections with fins distributed across different angular positions. Each fin segment directs airflow to specific zones of the ice tray, ensuring comprehensive coverage without creating centralized vortex patterns that would leave areas uncovered.
Solution Approach 2:
The airflow direction is changed from a conventional single-axis fan pattern to a multi-dimensional radial distribution pattern. The fins are arranged at various angular positions around the diffuser, projecting airflow in multiple directions simultaneously to cover the entire ice tray surface area uniformly.
2Reliability
If the defrost system operates while the ice maker is manufacturing ice pieces, then the evaporator can be maintained free of frost, but the temperature and harvesting variables are negatively affected delaying ice piece harvesting
Solution Approach 1:
The defrost operation is scheduled periodically and synchronized with the ice making cycle phases. The controller monitors the ice making cycle status and schedules defrost operations during periods when they will not interfere with ice harvesting, such as during water filling phases or between harvest cycles.
Solution Approach 2:
The controller uses feedback from sensors monitoring ice tray temperature, evaporator frost accumulation, and cycle timing to dynamically adjust the defrost scheduling. The system learns from operational patterns to optimize the timing of defrost cycles, ensuring they occur when minimum impact on ice production occurs.
3Reliability
If the defrost system provides heat to the evaporator to remove frost, then frost is removed from the evaporator, but the harvested ice pieces and structural components are warmed requiring additional cooling time
Solution Approach 1:
The defrost operation is scheduled in advance during identified optimal windows in the ice making cycle. The controller predicts when defrost will have minimal impact by analyzing cycle phases, and schedules defrost to occur during water filling or between harvest operations, preventing the need for extended post-defrost cooling.
Solution Approach 2:
The heating during defrost is localized primarily to the evaporator surface where frost accumulation occurs. The defrost heater is positioned to concentrate thermal energy where needed, minimizing heat transfer to adjacent ice tray components and structural elements that would require cooling.
4Device complexity
If the outlet diffuser directs airflow without proper configuration, then the fan can operate simply, but airflow vortex occurs preventing complete ice tray engagement
Solution Approach 1:
The outlet diffuser employs a radially symmetric design with curved fin surfaces that guide airflow smoothly in multiple directions. The radial geometry naturally distributes flow patterns spheroidally around the central axis, eliminating sharp corners and straight edges that would generate vortex formation while maintaining relatively simple manufacturing.
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
This solution enhances ice production efficiency by ensuring consistent and complete ice tray cooling, reducing ice harvesting time, and optimizing the ice making process by avoiding defrost cycle interruptions, thereby increasing daily ice production rates.
Implementation Method 1
a fan configured to direct an airflow out of the outlet diffuser and into the air inlet of the ice maker frame
Implementation Method 2
an evaporator that cools the air within the ice maker
Implementation Method 3
defrost systems are also included and are configured to defrost the evaporator. Such defrost systems provide heat to the evaporator to remove any frost formed thereon
Data Source
AI summary
An ice maker and method of operation for a refrigeration appliance, the ice maker including an ice maker frame having an air inlet provided at a first end thereof. An ice tray is rotatably secured to the ice maker frame and configured to form ice pieces therein. An air handler includes an outlet diffuser having a central body defined by a first wall- and a radially spaced apart second wall, wherein a plurality of radially extending fins are disposed between the first and second walls. Each of the fins is spaced apart, one from the other, along an outer peripheral surface of the first wall. In an installed position, the outlet diffuser is disposed directly adjacent the air inlet at the first end of the ice maker frame. A method is provided for synchronizing an ice making cycle of an ice making unit and a defrost cycle of an evaporator.