Ice Maker Ceramic Heater Assembly for Faster Ice Release Cycles
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Solution Overview
Problem
Conventional ice makers have low thermal efficiency, resulting in prolonged ice making cycle times due to the use of Calrod-type heating elements, which are inefficient in supplying heat to loosen ice from the mold.
Innovation Solution
The implementation of a heater assembly with a ceramic substrate featuring electrically resistive and conductive traces printed on it, aligned with ice lobes to efficiently supply heat and reduce ice making cycle times, utilizing thick film printing for uniform and predictable heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If Calrod-type heating elements are used, then the heater assembly can supply heat to loosen ice from the mold, but the thermal efficiency is low resulting in prolonged ice making cycle times
Solution Approach 1:
The patent changes the fundamental parameters of the heating element by transitioning from a Calrod-type design (coiled nichrome wire in magnesium dioxide within a metal sheath) to a ceramic-based heating element with resistive traces directly on the ceramic surface. This parameter change enables direct thermal coupling between the heating element and ice mold, eliminating thermal resistance barriers and significantly improving thermal efficiency while reducing ice making cycle times
Solution Approach 2:
The invention employs composite material structure by integrating resistive heating traces (conductive material) directly onto the ceramic substrate surface. This composite approach combines the high thermal conductivity and structural stability of ceramic with the electrical resistivity needed for heating, creating a unified heating element that achieves both structural integrity and superior thermal performance
2Manufacturing precision
If heating elements are positioned along the outer surface of the ice mold, then heat can be supplied to release ice cubes, but the heat distribution is uneven resulting in inefficient heating
Solution Approach 1:
The patent applies local quality by positioning resistive heating traces at specific locations on the ceramic substrate that correspond to the lobes of the ice mold. This localized heating approach concentrates thermal energy precisely where needed (at the ice-lube contact points) rather than distributing heat uniformly across the entire mold surface, thereby improving both heat distribution uniformity at critical locations and overall heating efficiency
Solution Approach 2:
The invention transitions from a three-dimensional Calrod-type heating element (coiled wire within insulation within a sheath) to a two-dimensional planar heating structure where resistive traces are deposited directly on the flat ceramic substrate surface. This dimensional reduction enables closer proximity to the mold surface and more precise control over heat distribution patterns, improving thermal efficiency and productivity
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 ceramic heater assembly significantly reduces ice making cycle times by providing precise and efficient heat application, achieving faster heating and cooling cycles with improved thermal efficiency compared to conventional systems.
Implementation Method 1
The heater assembly includes a plurality of heating elements. Each of the plurality of heating elements is aligned with a corresponding lobe of the plurality of lobes for supplying heat to ice cubes formed in the lobes
Implementation Method 2
The heater assembly includes a heater having a ceramic substrate, and the plurality of heating elements of the heater assembly are formed by a plurality of electrically resistive traces printed on the ceramic substrate of the heater
Data Source
AI summary
An ice maker includes an ice mold having an inner surface and an outer surface. The inner surface of the ice mold is configured to retain water for forming ice cubes in the ice mold. The ice mold includes a plurality of ice lobes each shaped to form a respective ice cube in the ice mold. A heater assembly is positioned on the outer surface of the ice mold. In some embodiments, each of a plurality of heating elements of the heater assembly is aligned with a corresponding lobe of the plurality of lobes for supplying heat to ice cubes formed in the lobes for releasing the ice cubes from the ice mold. In some embodiments, the heater assembly includes a heater having a ceramic substrate and one or more electrically resistive traces and electrically conductive traces thick film printed on the ceramic substrate.