Modular ice system
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Solution Overview
Problem
The production of different sizes of ice-making machines incurs substantial tooling costs due to the need for various ice-tray configurations, and existing technologies lack efficient methods for manufacturing and managing ice trays with reduced complexity and cost.
Innovation Solution
A modular ice-tray design using separately fabricated cups with laterally extending channels that can be assembled into various configurations, combined with a thermoplastic frame for efficient manufacturing and reduced tooling costs, along with a sensor system for detecting ice formation and a heater for releasing ice cubes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different sizes of die cast metal ice-trays are manufactured to fit various refrigerator sizes, then adaptability to different consumers is improved, but tooling costs increase substantially
Solution Approach 1:
The ice tray is divided into multiple individual cup modules that can be independently manufactured and then assembled in different configurations. Each cup module is a standardized component that can be produced using a single mold, eliminating the need for multiple specialized dies for different tray sizes. These modular cups are arranged in frames to create trays with varying numbers of cubes (6, 12, 18, 21, or more), allowing manufacturers to offer different tray configurations without incurring additional tooling costs.
2Ease of manufacture
If a modular design with separately fabricated cups is used, then manufacturing efficiency is improved, but device complexity increases
Solution Approach 1:
The cup modules are designed with universal features including standardized rims that fit various frame types, integrated water channels that work with different tray configurations, and uniform attachment mechanisms. This universality allows the same cup design to be used across multiple tray sizes and refrigerator models, simplifying the overall system despite the modular construction. The standardized interfaces reduce assembly complexity while maintaining manufacturing efficiency.
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 allows for the efficient manufacturing of ice trays in various sizes with reduced tooling costs, enables faster ice cycling, and improves ice release efficiency by directly sensing ice formation and using a simple heating mechanism, thus addressing the need for cost-effective and versatile ice-tray production.
Implementation Method 1
the ice-tray will be a metal die-cast part incorporating an electrical resistance heater which heats the ice-tray to above the melting point of water to release the ice
Implementation Method 2
a sensor in the cup for sensing ice formation in the cup
Data Source
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AI summary
An ice-tray for ice-making machines is formed by modular fabricated cups that can assembled together within a frame to create an ice-tray of arbitrary dimensions allowing a sharing of components among a variety of ice-tray sizes. Individual cups may include ice formation sensors or heaters or may be heated by an induction heating system.