Refrigerator with multi-zone ice maker
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Solution Overview
Problem
Conventional ice makers in refrigerators lack precise control over heating and ice harvesting, leading to inefficiencies and unnecessary space usage due to non-precision heating systems and excess materials.
Innovation Solution
A multi-zone ice maker system with independently controllable heaters and temperature sensors in each zone, allowing for staggered ice harvesting and reduced noise and energy consumption, using a reversible motor and rake fingers for precise ice removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single heater is used for the entire mold body, then the structure is simple, but precise control over ice harvesting is not achieved
Solution Approach 1:
The mold body is divided into multiple heating zones (first heating zone, second heating zone, third heating zone) with independent heaters for each zone. This segmentation enables precise control over which portions of ice are harvested, allowing selective harvesting based on demand while maintaining simple overall structure through modular design
Solution Approach 2:
The system dynamically activates specific heating zones based on real-time ice demand and harvesting requirements. The controller selectively energizes only the necessary heating zones rather than operating all heaters continuously, enabling adaptive control that balances precision with energy efficiency
2Measurement precision
If the calrod heater is positioned in the lower portion of the mold body, then the heater structure is simple, but the heating control is not precise
Solution Approach 1:
Instead of a single calrod heater in the lower portion, the system employs multiple distributed heating zones with independent heaters positioned throughout the mold body. Each heater is strategically placed to provide localized heating control for its specific zone, achieving precise thermal management without excessive structural complexity
Solution Approach 2:
Each heating zone has its own heater positioned to provide localized heating where needed. This allows different portions of the mold body to have different thermal characteristics and control independence, enabling precise control over ice harvesting in specific areas without affecting other zones
3Productivity
If the entire tray of ice is harvested at once, then the harvesting process is simple, but unnecessary ice is removed and space is wasted
Solution Approach 1:
The ice harvesting process is segmented into zone-specific operations. The controller can activate heating and harvesting for only the necessary zones based on demand, allowing partial harvesting of specific ice portions while leaving other ice intact. This eliminates the need to harvest the entire tray at once, reducing ice loss and optimizing space utilization
Solution Approach 2:
The system performs partial harvesting actions by selectively activating only the heating zones and harvesting mechanisms needed for current demand. Rather than harvesting all ice uniformly, the system applies heating and harvesting actions only where and when needed, improving efficiency while minimizing unnecessary ice removal
4Measurement precision
If the calrod heater is on anytime energized, then the heater operation is simple, but precise control and timing are not achieved
Solution Approach 1:
The heater control system dynamically adjusts operation based on real-time conditions. The controller monitors ice formation, temperature, and harvesting needs to selectively activate specific heating zones only when and where needed. This dynamic control achieves precise timing and temperature management without requiring overly complex control logic
Solution Approach 2:
The heating operation is implemented as periodic rather than continuous. The controller activates heating zones in cycles based on ice formation stages and harvesting requirements, allowing precise control over when heating occurs. This periodic action pattern enables accurate timing control while maintaining relatively simple heater operation
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
Enables precise control over ice generation and harvesting, optimizing space and energy usage, and reducing noise and energy consumption by allowing independent control of each ice-making zone.
Implementation Method 1
a heater may be used to melt the surfaces of the ice in contact with the trays to facilitate release of the ice from the trays
Implementation Method 2
The heat generated by the calrod heater then travels through the mold body to warm the ice trays in order to release the ice
Implementation Method 3
the latter maintained at a temperature below freezing for longer-term storage of frozen foods
Data Source
AI summary
A refrigerator includes a cabinet with one or more food compartments and one or more doors closing the food compartments and an ice maker located in the cabinet to produce ice. The ice maker includes a mold body for forming ice, the mold body having multiple cups, where each cup has an opening for receiving water to be frozen within the cup. The mold body is divided into at least a first zone and a second zone and the ice maker including at least a first heater and a second heater configured to provide heat to the first and second zones of the mold body, respectively, and a controller configured to harvest ice from the first zone independently of the second zone by actuating the first heater to provide heat to the first zone of the mold body to facilitate a release of ice from the first zone.