Harness free ice maker system
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Solution Overview
Problem
Existing ice makers in refrigerators require a wiring harness to pass through the insulated freezer wall, which is costly, unwieldy, and poses electrical safety risks due to potential water exposure and connector disconnection.
Innovation Solution
An ice making apparatus using magnetic power transfer from a primary coil outside the freezer to a secondary coil inside, eliminating the need for a wiring harness and enabling wireless communication for control signals, thus simplifying installation and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wiring harness is used to deliver power to the ice maker through the freezer wall, then electrical power can be supplied to the motor and heater, but the installation becomes costly and unwieldy with increased safety risks
Solution Approach 1:
The patent replaces the mechanical wiring harness system with an electromagnetic induction system. A primary coil mounted on the exterior of the freezer wall generates an oscillating magnetic field that induces current in a secondary coil inside the freezer, eliminating the need for physical wire connections through the wall. This substitution resolves the contradiction by maintaining power delivery while removing the safety hazards and installation complexity of penetrating wiring harnesses.
Solution Approach 2:
The patent introduces an electromagnetic field as an intermediary medium to transfer power across the freezer wall barrier. The primary coil converts electrical energy to an oscillating magnetic field, which then induces current in the secondary coil on the other side of the wall. This intermediary approach allows power transfer without direct physical connection, eliminating the need for harnesses that penetrate the wall and create safety risks.
2Ease of manufacture
If a wiring harness with connector passes through the freezer wall, then power can be delivered to the ice maker, but the connector requires shielding and complex sealing to prevent water ingress
Solution Approach 1:
The patent eliminates the mechanical connector system entirely by using electromagnetic induction for power transfer. Since no physical wires need to pass through the freezer wall, there are no connectors requiring shielding or sealing against water ingress. This substitution dramatically simplifies manufacturing by removing the complex assembly of sealed connector housings and gaskets.
3Ease of operation
If a large hole is cut in the freezer wall for the harness connector, then the connector can be installed, but the hole requires extensive sealing with gasket and adhesive
Solution Approach 1:
The patent replaces the mechanical wire-pushing-through-wall method with electromagnetic field coupling. The primary coil is mounted on the exterior surface without penetrating the wall, and the secondary coil is positioned inside the freezer adjacent to the wall. The oscillating magnetic field penetrates the non-conductive wall material to induce current in the secondary coil, eliminating the need for large holes and extensive sealing operations.
4Adaptability or versatility
If a wiring harness is used to control the water valve, then the valve can be operated from inside the freezer, but the control lines must pass through the freezer wall
Solution Approach 1:
The patent makes the electromagnetic coupling system universal by using it for both power delivery and control signal transmission. The same primary and secondary coils that transfer power also carry modulated control signals for the water valve and other ice maker functions. This multi-functionality eliminates the need for separate control wiring through the wall, as all signals are transmitted via the electromagnetic field across the wall barrier.
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 simplifies the installation of ice makers, boosts electrical safety, and reduces assembly time by using inductive coupling for both power and data transmission, eliminating the need for power and valve control lines to pass through the freezer compartment wall.
Implementation Method 1
A secondary coil is supported by the housing on the sidewall to receive electrical energy from an oscillating magnetic field passing through the freezer cabinet wall
Implementation Method 2
a rectifier circuit converts the received electrical energy to a voltage supplying the logic circuitry and electric motor
Data Source
AI summary
An ice maker is provided that may include cooperating primary and secondary coils arranged on opposite sides of a freezer cabinet wall for wirelessly transmitting electrical power through the freezer cabinet wall to energize various ice maker components. During the wireless electrical power transmission, a data/control signal may be superimposed on the electrical power waveform to allow wireless transmission of the control signal, which can be processed by a logic circuitry for implementing component control methodologies.