Optical Ice Level Sensing With Anti-Frost Heating in Refrigerators

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Solution Overview

Problem

In refrigerators with ice makers, mechanical full ice detection levers can become frozen, leading to incorrect determination of ice container fullness, resulting in continuous ice supply and overflow.

Innovation Solution

An ice detecting apparatus with a transmitter and receiver module, including optical elements and a heater made of electroconductive material, is used to accurately detect the ice-full state by preventing frost formation and ensuring reliable operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a mechanical full ice detection lever is used, then the structure is simple, but the detection reliability deteriorates when the lever becomes frozen

Engineering Contradiction:

Improvedetection structureVSAvoidice full detection

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces the mechanical full ice detection lever with an optical detection system consisting of a transmitter and receiver. The transmitter emits light that passes through the ice container, and the receiver detects the light intensity. When ice reaches a certain level, it blocks the light path, causing the receiver to detect a change in light intensity, thereby determining the container is full. This optical system eliminates the mechanical components that are prone to freezing and malfunction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If the mechanical detection lever is used, then the device is simple to manufacture, but the detection precision deteriorates due to frost formation

Engineering Contradiction:

Improvedetection deviceVSAvoidice level detection

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The optical detection system replaces the mechanical lever, eliminating the issue of frost formation affecting mechanical movement. The transmitter and receiver are positioned to detect light through the ice container, and since they are not mechanical contact components, they are not affected by frost accumulation, ensuring consistent and precise detection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces light as an intermediary medium for detection. Instead of direct mechanical contact between the detection lever and ice, the system uses light transmission through the ice container as an intermediary to indirectly detect ice level. This indirect detection method avoids the problems of direct mechanical interaction with frozen conditions.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If no heater is provided, then the device complexity is low, but frost formation occurs on the detection sensor

Engineering Contradiction:

Improvesensor structureVSAvoidfrost formation on sensor

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The heater acts as an intermediary protective element between the cold environment and the detection sensor. By positioning the heater near the transmitter and receiver, it creates a localized thermal barrier that prevents frost formation on the optical components without requiring the entire sensor assembly to be heated or complex anti-frost mechanisms.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the temperature parameter locally around the detection sensor by introducing a heater. This creates a micro-environment with higher temperature than the surrounding freezing conditions, preventing frost formation on the optical components while maintaining the overall cold environment needed for ice storage.

Inventive Principle:

Principle #35Parameter changes

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 apparatus effectively prevents frost formation on the detection sensor, allowing for accurate detection of the ice-full state, thereby preventing ice overflow and ensuring proper operation of the ice maker.

Implementation Method 1

at least one of the transmitter module or receiver module includes at least one optical element and at least one heater, and the heater is made of an electroconductive heating material

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

The transmitter module is separated by a prescribed distance from the receiver module. At least one of the transmitter module or receiver module includes at least one optical element

Methodology Applied

Scientific EffectOptical detection: Light

Data Source

PatentUS8959939B2Refrigerator and ice maker with optical sensor to detect ice level

Publication Date: 2015.02.24 LG ELECTRONICS INC

AI summary

An ice detecting apparatus for a refrigerator the apparatus includes an ice maker, an ice container to collect ice made by the ice maker, and an ice detecting sensor to detect an amount of ice stored in the ice container. The ice detecting sensor has a transmitter module provided on one side of the ice maker and a receiver module provided on another side of the ice maker. The transmitter module is separated by a prescribed distance from the receiver module. At least one of the transmitter module or receiver module includes at least one optical element and at least one heater, and the heater is made of an electroconductive heating material.