Optical Ice Bin Level Sensing for Bottom Freezer Access

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Solution Overview

Problem

Existing refrigeration appliances with ice makers and storage bins face issues such as physical contact-based ice level sensing leading to ice cubes being displaced and unnecessary movement of the ice bin, causing service calls and increased user effort.

Innovation Solution

A non-contact ice level sensing system using an emitter and receiver component, where the emitter is mounted between the ice bin and the food storage compartment, and the receiver is mounted on the opposite side, allowing the ice bin to slide and occupy less than full width, preventing physical contact and enabling independent sliding of compartments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mechanical bail arm is used to sense ice level, then ice production can be shut off when the bin is full, but ice cubes may be displaced and pushed into the storage area when the basket is moved

Engineering Contradiction:

Improveice level sensing reliabilityVSAvoidice cube displacement

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical bail arm sensing system with an optical sensing system using a light source and photodetector. The optical sensor detects ice level through a window in the bin wall without physical contact, eliminating the problem of ice cubes being pushed into the storage area while maintaining reliable ice level detection for shutting off ice production

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an optical intermediary (light beam) between the sensing system and the ice cubes. The light beam passes through a window in the bin wall to detect ice level, serving as a non-contact mediator that eliminates direct mechanical interaction between the sensing mechanism and ice cubes, thereby preventing ice cube displacement

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the ice bin is mounted to move with the storage basket, then the basket can be pulled out for access, but the ice bin undergoes unnecessary movement requiring more user force

Engineering Contradiction:

Improvebasket accessibilityVSAvoiduser force required

Core Design Contradiction:

Ease of operationVSForce

Solution Approach 1:

The patent segments the mounting system into two independent parts: the storage basket that moves on front rails for accessibility, and the ice bin that moves independently on rear rails. This segmentation allows the basket to be pulled out for access while the ice bin remains stationary or moves minimally, reducing the force required by the user

Inventive Principle:

Principle #1Segmentation

3Area of stationary object

If the ice bin occupies full width of the freezer compartment, then space utilization is maximized, but the bail arm may rake ice cubes rearward into the storage area

Engineering Contradiction:

Improveice bin widthVSAvoidice cube displacement into storage area

Core Design Contradiction:

Area of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical bail arm with an optical sensing system that detects ice level through a window in the bin wall. This substitution allows the ice bin to maintain its width for space utilization while eliminating the mechanical interaction that causes ice cubes to be raked rearward into the storage area

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 ice cube displacement and reduces unnecessary movement, enhancing user experience by eliminating service calls and reducing user effort, while ensuring accurate ice level sensing without physical contact.

Implementation Method 1

An emitter component is attached to the first structural member to emit a beam of light across an upper portion of the bin

Methodology Applied

Scientific EffectLight: Light

Implementation Method 2

a receiver component is attached to the second structural member opposite the emitter component to receive the beam of light

Methodology Applied

Scientific EffectLight: Light

Data Source

PatentUS7610772B2Ice level sensing system for a bottom freezer refrigerator

Publication Date: 2009.11.03 WHIRLPOOL CORP

AI summary

A refrigeration appliance is provided with a freezer compartment accessible through an openable door, the freezer compartment extending between two side walls. An ice bin is slidably mounted in the freezer compartment occupying a width of the freezer compartment, less than a full width between the two side walls. A food storage compartment is slidably mounted in the freezer compartment with at least a portion horizontally adjacent to the ice bin, and slidable independently of the ice bin. A non-contact ice level sensing apparatus having an emitter component and a receiver component is provided, with one of the components mounted between the ice bin and the food storage compartment and the other of the components mounted on an opposite side of the ice bin from the food storage compartment.