Ice Maker Time-of-Flight Sensor and Surface Tension Water Distribution
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Solution Overview
Problem
Conventional ice makers face inefficiencies in ice distribution and harvesting due to suboptimal water flow and ice bin sensing mechanisms, leading to uneven ice formation and inaccurate ice level detection.
Innovation Solution
The ice maker incorporates a novel water distributor design with a two-piece configuration, featuring a bottom and top distributor piece that directs water uniformly across the freeze plate, and a time-of-flight sensor for precise ice level detection, allowing for improved ice formation uniformity and accurate bin filling monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If water is directed to flow downward along the front of the freeze plate, then ice formation uniformity is improved, but water flow control complexity increases
Solution Approach 1:
The bottom wall incorporates a downwardly curving surface tension curve that utilizes surface tension forces to direct water flow downward along the freeze plate. This curved geometry naturally guides water flow without requiring additional mechanical components, achieving uniform ice formation while maintaining simple device structure
Solution Approach 2:
The invention replaces complex mechanical water flow control mechanisms with surface tension-based flow control. The surface tension curve on the bottom wall passively directs water flow through capillary and surface tension effects, eliminating the need for pumps, valves, or complex flow distribution mechanisms
2Measurement precision
If a time-of-flight sensor is used for ice level detection, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The invention replaces mechanical or capacitive ice level sensing mechanisms with a time-of-flight optical sensor. This optical sensing method uses light travel time measurements to detect ice level, providing high measurement precision without mechanical contact or complex electrical field configurations
Solution Approach 2:
The time-of-flight sensor uses light as an intermediary to detect ice level non-contactually. The optical pulse travels through air to reflect off the ice surface and return to the sensor, enabling accurate measurement without physical interaction with the ice or water
3Manufacturing precision
If the distributor is configured with a surface tension curve, then water distribution uniformity is improved, but manufacturing complexity increases
Solution Approach 1:
The invention changes the geometric parameters of the distributor bottom wall to include a specific downwardly curving surface tension curve with optimized radius and profile. This geometric parameter optimization ensures uniform water distribution through surface tension effects while maintaining compatibility with standard manufacturing processes for plastic or metal components
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 solution enhances ice formation uniformity and efficiency by ensuring consistent water distribution and accurate ice level sensing, optimizing ice production and bin utilization.
Implementation Method 1
The downstream end portion of the bottom wall defines a downwardly curving surface tension curve. The downwardly curving surface tension curve is configured so that surface tension causes the water imparted through the distributor to adhere to the curve and be directed downward by the curve toward the top end portion of the freeze plate.
Implementation Method 2
A time-of-flight sensor is configured to: emit, at a first time, an optical pulse signal through the sensor opening toward the ice bin; detect, at a second time, a photon of the optical pulse signal that returns to the time-of-flight sensor through the sensor opening after reflecting off of one of a floor of the ice bin and ice in the ice bin, and determine a duration between the first time and the second time
Data Source
AI summary
An ice maker has a bottom wall with a sensor opening. A time-of-flight sensor is supported in relation to the bottom wall such that the time-of-flight sensor can an optical pulse signal through the sensor opening toward the ice bin and subsequently detect a photon of the optical pulse signal that returns to the time-of-flight sensor through the sensor opening after reflecting off of one of a floor of the ice bin and ice in the ice bin. The time of flight sensor is configured to determine a duration between the emission of the optical pulse and the detection of the reflected photon(s). Based on the determined duration, the time-of-flight sensor or another processor can determine an amount of ice in the ice bin. The ice maker can be configured so that the time-of-flight sensor is removable, allowing a window pane of the time-of-flight sensor to be periodically cleaned.