Phase Change Thermal Battery for Door-Mounted Ice Making

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Solution Overview

Problem

Bottom mount refrigerators face inefficiencies due to the placement of ice makers within the fresh food compartment, which reduces storage space and increases energy consumption by relying on cold air from the freezer compartment for ice production, leading to energy wastage and potential air leakage.

Innovation Solution

Integration of a thermoelectric cooler on the fresh food door with a thermal battery using phase change materials to cool the ice maker independently, eliminating the need for air from the freezer compartment and optimizing energy use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the ice maker is positioned within the fresh food compartment, then ice making is convenient and accessible, but the available storage space within the fresh food compartment is reduced

Engineering Contradiction:

Improveice making accessibilityVSAvoidfresh food storage space

Core Design Contradiction:

Ease of operationVSVolume of stationary object

Solution Approach 1:

The ice maker is separated from the main fresh food compartment and positioned on the door instead. This segmentation allows the ice making function to be accessible while preserving the full storage volume of the fresh food compartment, as the ice maker occupies door space rather than interior compartment space.

Inventive Principle:

Principle #1Segmentation

2Productivity

If cold air from the freezer compartment is directed to cool the ice maker, then ice production is effective, but energy consumption increases due to the additional cooling load on the freezer compartment

Engineering Contradiction:

Improveice production efficiencyVSAvoidrefrigerator energy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The ice maker cooling system is extracted from the freezer compartment's air cooling system. Instead of using cold air from the freezer compartment, the ice maker now has its own independent cooling mechanism using a thermoelectric cooler and phase change material, eliminating the additional cooling load on the freezer compartment and reducing overall energy consumption.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

A phase change material acts as an intermediary between the thermoelectric cooler and the ice maker water. The phase change material absorbs heat from the water during phase transition, providing efficient cooling without requiring direct air flow from the freezer compartment, thus reducing energy consumption while maintaining effective ice production.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Temperature

If a fan is used to direct cooled air to the ice maker, then cooling is provided, but the cooled air may warm or escape, creating the need for even more cooled air and increasing energy consumption

Engineering Contradiction:

Improveice maker cooling temperatureVSAvoidcooling energy waste

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The fan-based air circulation system is removed from the ice maker cooling process. The new system uses a thermoelectric cooler with phase change material that directly cools the water in the ice maker without requiring air circulation, eliminating the energy waste associated with fan operation and potential air escape.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The phase change material provides self-regulating cooling through its phase transition properties. As the material changes phase, it automatically absorbs heat at a constant temperature, providing consistent cooling to the ice maker without requiring active control or additional energy input to maintain temperature.

Inventive Principle:

Principle #25Self-service

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 allows for efficient ice production on the fresh food door, conserving space and reducing energy consumption by utilizing a self-contained cooling system that absorbs heat from the thermoelectric cooler, thereby maintaining efficient operation without relying on the freezer compartment's cold air.

Implementation Method 1

A thermal battery is positioned on the fresh food door adjacent the thermoelectric cooler to absorb heat from the thermoelectric cooler

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

a phase change material to cool the ice maker independently

Methodology Applied

Scientific EffectHeat absorption: Latent Heat

Implementation Method 3

a thermoelectric cooler on the fresh food door with a thermal battery using phase change materials to cool the ice maker independently

Methodology Applied

Scientific EffectThermoelectric effect: Peltier Effect

Data Source

PatentUS9016070B2Phase change materials for refrigeration and ice making

Publication Date: 2015.04.28 WHIRLPOOL CORP

AI summary

A bottom mount refrigerator is provided including a thermal battery or phase change material positioned within the refrigerator or freezer in order to increase energy efficiency and compartment sizes of the refrigerator. The thermal battery can be used with an ice maker to aid in removing heat from the water in the ice maker to produce ice. Furthermore, the phase change material or thermal battery may be used with a thermoelectric cooler to aid in ice production. The phase change material may be tuned to various temperatures according to the desired use of the phase change material, as well as the location of the thermal battery or phase change material. Other embodiments include positioning the phase change material in the liner of the compartments or in thermal storage units in order to further increase the energy efficiency of the refrigerator.