Ice Maker Hall Sensor Design to Prevent Moisture and Dust Malfunction

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Solution Overview

Problem

Ice makers are susceptible to malfunction due to moisture penetration, which affects the operation of electric components and sensors, leading to potential breakdowns and fires, especially during test runs and actual use in refrigerators.

Innovation Solution

An ice maker design utilizing a printed circuit board with a high-sensitivity Hall sensor that operates through a non-contact magnetic field, eliminating the need for external switches and reducing moisture and dust ingress, and allowing for easy attachment and detachment without screws.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional contact-based sensors and switches are used in the drive box, then the ice maker can detect operational states, but moisture and dust can penetrate through through-holes and cause malfunction or breakdown

Engineering Contradiction:

Improvesensor operation reliabilityVSAvoidmoisture and dust penetration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces traditional contact-based mechanical switches with a magnetic field-based detection system. A magnet is attached to the moving lever, and a Hall sensor on the printed circuit board detects the magnet's position through non-contact magnetic field sensing. This eliminates the need for through-holes and physical contacts, preventing moisture and dust penetration while maintaining reliable operational state detection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a magnetic field as an intermediary between the moving lever and the sensor. The magnet on the lever creates a magnetic field that penetrates the non-conductive printed circuit board material, allowing the Hall sensor to detect lever position without direct physical contact or through-holes, thus isolating the electronic components from moisture and dust.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If through-holes are created in the drive box for sensor installation, then sensors can detect operational states, but dust and moisture can enter the drive box and cause breakdown

Engineering Contradiction:

Improveoperational state detection accuracyVSAvoiddust and moisture ingress

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces through-hole mounted contact switches with a Hall sensor that detects magnetic fields through the non-conductive printed circuit board material. The magnet attached to the moving lever creates a magnetic field that passes through the board, enabling precise position detection without creating openings that would allow dust and moisture ingress.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Stability of the object's composition

If multiple fixation screws are used to attach the printed circuit board, then the board is securely fixed, but the structure becomes complex and assembly is difficult

Engineering Contradiction:

Improveprinted circuit board fixation stabilityVSAvoidfixation structure complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent merges the fixation function into the molded housing structure itself. The printed circuit board is designed with recesses that fit into corresponding protrusions on the housing, and elastic members provide snap-fit retention. This integrated design eliminates the need for separate fixation screws, reducing assembly complexity while maintaining stable board attachment.

Inventive Principle:

Principle #5Merging (Combining)

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

Prevents erroneous operations and thorough protection against moisture and dust, enhancing operational reliability and accuracy by reducing errors from accumulative tolerances and component deviations.

Implementation Method 1

a position detection sensor being provided on the printed circuit board in such a manner that an electric contact point is established according to trajectory followed by the moving magnet

Methodology Applied

Scientific EffectHall sensor magnetic field detection: Hall Effect

Data Source

PatentUS12571574B2Ice maker and refrigerator including the same

Publication Date: 2026.03.10 DAECHANG

AI summary

Proposed are an ice maker and a refrigerator including the ice maker. The ice maker includes a drive motor arranged inside a casing and configured to rotate an ice-making tray or an ejector pin, a gear set operating in unison with the drive motor, an in-unison operating lever provided to operate in unison with the gear set, a magnet being provided on one side of the in-unison operating lever, and a printed circuit board arranged to one side of the in-unison operating lever, a position detection sensor being provided on the printed circuit board in such a manner that an electric contact point is established according to trajectory followed by the moving magnet.