Nugget Ice Maker Air Cooling Design to Reduce Assembly Complexity
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Solution Overview
Problem
Existing nugget ice makers require complex and expensive unitary mold bodies with liquid cooling systems that are difficult to assemble and maintain, and often leak, especially when mounted on refrigerator doors, where liquid refrigerant lines are hard to install and maintain.
Innovation Solution
The design includes a casing with a discrete upper flange and extruder die, using air as a heat exchange medium through a cooling air duct with fins, allowing for easier assembly and energy efficiency in ice production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a liquid cooling system is used to draw heat from the mold body, then heat exchange effectiveness is improved, but assembly difficulty and maintenance complexity increase
Solution Approach 1:
The patent replaces the liquid cooling system with an air cooling system. Instead of using liquid refrigerant lines that require complex assembly and maintenance, the invention uses air as the cooling medium that flows through passages in the mold body, eliminating the need for liquid cooling components and their associated assembly and maintenance challenges.
Solution Approach 2:
The patent utilizes air flow (pneumatics) to achieve cooling. Air is directed through cooling passages formed in the mold body, using the movement of gas to transfer heat away from the water being frozen, thereby achieving effective heat exchange without requiring liquid cooling systems.
2Strength
If a unitary mold body is used, then structural integrity is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent divides the mold body into multiple separate components rather than using a single unitary structure. The mold body is segmented into distinct parts that can be manufactured separately and then assembled together, reducing manufacturing complexity and cost while maintaining the necessary structural integrity through proper design of the segmented components and their connections.
3Temperature
If liquid refrigerant lines are installed for door-mounted ice makers, then cooling function is achieved, but installation and maintenance difficulty increase
Solution Approach 1:
The patent eliminates liquid refrigerant lines by substituting them with an air cooling system. Air cooling passages are integrated into the mold body structure, allowing cooling air to be distributed directly to the ice-making components without requiring complex liquid line installations, thereby greatly simplifying both installation and maintenance operations.
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 configuration simplifies assembly, reduces energy consumption, and minimizes the risk of leaks, while maintaining effective ice production, making the ice maker more affordable and easier to maintain.
Implementation Method 1
During ice making operations, heat is generally conducted away from water within the mold body
Implementation Method 2
A liquid cooling system is commonly used to draw heat from the mold body
Implementation Method 3
The cooling air duct may define a plurality of air openings in fluid communication with the air passage. The plurality of fins may be in thermal communication with the chamber
Data Source
AI summary
A refrigerator appliance and ice maker apparatus are included herein. The ice maker apparatus may include a casing, an auger, a discrete flange, and an extruder die. The casing may define a chamber about a central axis. The casing may extend along the central axis between a top portion and a bottom portion. The casing may include a first material. The auger may be disposed within the chamber of the casing. The discrete flange may be selectively mounted on the casing. The discrete flange may include a second material that is unique from the first material. The extruder die may be attached to the discrete upper flange and positioned above the casing.