Ice Maker Evaporator Assembly with Covered Back and Dual Insulation

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Solution Overview

Problem

Typical ice makers suffer from inefficiencies due to extraneous heat transfer on the back surfaces of evaporator assemblies, moisture-related corrosion, and contamination from airborne contaminants, which reduce their efficiency and lead to costly maintenance issues.

Innovation Solution

The evaporator assembly features a covered back side with a serpentine tube insulated by a flexible liquid coating and a second layer of insulation, eliminating the need for plating and reducing heat loss, while a cavity filled with foam further minimizes heat transfer and corrosion risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If the back side of the evaporator is left exposed, then heat transfer efficiency is maintained, but extraneous heat transfer and moisture-related corrosion occur

Engineering Contradiction:
Improveheat lossVSAvoidcorrosion resistance
Core Design Contradiction:
Loss of energyVSReliability

Solution Approach 1:

The patent extracts the problematic back surface of the evaporator from the ice-making process by covering it with an evaporator housing. This isolation prevents extraneous heat transfer and moisture contact with the refrigerant tubing, eliminating the source of corrosion while maintaining efficient heat transfer on the exposed front surface.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces an intermediary evaporator housing that acts as a barrier between the refrigerant tubing and the external environment. This housing prevents direct contact between moisture/air and the tubing, eliminating corrosion pathways while allowing controlled heat transfer through the evaporator pan.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If plating is applied to the evaporator, then corrosion resistance is improved, but manufacturing complexity and cost increase

Engineering Contradiction:
Improvecorrosion resistanceVSAvoidmanufacturing complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes the requirement for plating by extracting the refrigerant tubing from direct exposure to corrosive environments. The evaporator housing creates a protected environment where bare copper tubing can operate without corrosion, eliminating the need for additional plating processes.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces expensive and complex plating processes with a simpler evaporator housing structure. The housing provides corrosion protection through its physical barrier rather than through costly metallurgical treatments, simplifying manufacturing.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

3Loss of energy

If insulation is added to the serpentine tube, then heat loss is reduced, but device complexity increases

Engineering Contradiction:
Improveheat lossVSAvoidstructural complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The patent combines the evaporator pan and evaporator housing into a single integrated structure that serves multiple functions: it supports the serpentine tubing, provides insulation, and protects against corrosion. This merging eliminates the need for separate insulation components while maintaining thermal efficiency.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The evaporator housing serves multiple functions simultaneously: it acts as a structural support for the tubing, provides thermal insulation, prevents corrosion, and defines the evaporator assembly boundaries. This multi-functionality reduces overall device complexity despite adding insulation capabilities.

Inventive Principle:
Principle #6Universality (Multi-functionality)

4Ease of operation

If the evaporator is left open, then accessibility for installation is maintained, but contamination from airborne contaminants occurs

Engineering Contradiction:
Improveinstallation accessibilityVSAvoidcontamination
Core Design Contradiction:
Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent extracts the refrigerant tubing from direct exposure to airborne contaminants by enclosing it within the evaporator housing. This isolation prevents contamination while the housing design maintains installation accessibility through standard assembly procedures.

Inventive Principle:
Principle #2Taking out (Extraction)

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 design enhances the efficiency of ice production by reducing heat loss and corrosion, eliminates the need for costly plating, and prevents contamination, resulting in increased ice output with reduced energy consumption.

Implementation Method 1

A first layer of insulation is formed on the serpentine tubing. An evaporator housing having a housing back wall and housing left, right, top and bottom sidewalls extending from the housing back wall is attached to the evaporator pan and covers serpentine tubing. A second layer of insulation is formed on top of the first layer of insulation

Methodology Applied
Scientific EffectThermal Insulation: Thermal Insulation

Implementation Method 2

Attached to the back side of the evaporator pan is a serpentine tube through which cold refrigerant flows to lower the temperature of the evaporator so that ice can be formed therein

Methodology Applied
Scientific EffectHeat Exchanger: Heat Exchanger

Implementation Method 3

evaporator assemblies in typical ice makers will condense and freeze moisture in the air inside the ice maker

Methodology Applied
Scientific EffectCondensation: Condensation

Implementation Method 4

a cavity filled with foam further minimizes heat transfer and corrosion risks

Methodology Applied
Scientific EffectThermal Insulation: Thermal Insulation

Data Source

PatentUS12117224B2Sanitary evaporator assembly
Publication Date: 2024.10.15 TRUE MFG CO INC
  • US12117224B2 patent drawing
  • US12117224B2 patent drawing
  • US12117224B2 patent drawing

AI summary

An ice maker evaporator assembly having an evaporator pan with a back wall and left, right, top and bottom sidewalls extending from the back wall, and a freeze plate located within the evaporator pan. Refrigerant tubing is thermally coupled to the back wall of the evaporator pan opposite the left, right, top and bottom sidewalls. A first layer of insulation is formed on the refrigerant tubing. An evaporator housing having a housing back wall and housing left, right, top and bottom sidewalls extending from the housing back wall is attached to the evaporator pan and covers refrigerant tubing. A second layer of insulation is formed on top of the first layer of insulation.