Ice-ejection mechanisms and methods for icemakers, and icemakers incorporating the same

Abstract

Icemakers that make ice shapes and that each include at least one mold, at least one pusher, and a drive mechanism that drives at least one of the pusher and at least a portion of each mold so as to eject the ice shape(s) from the mold. In some embodiments, each mold includes an elastic wall that the pusher deforms to eject the ice shape. In some embodiments, each mold is a split mold having mold halves, and the drive mechanism moves at least one of the mold halves during ejection operations. In some embodiments, each mold has a self-closing opening for each ice-shape chamber of the mold that, during ejection operations, opens to allow the ice shape to pass therethrough and then self-closes after the ice shape has exited the mold. In some embodiments, an icemaker of this disclosure includes features for making clear, i.e., non-cloudy, ice shapes.

Description

ICE-EJECTION MECHANISMS AND METHODS FOR ICEMAKERS, AND ICEMAKERS INCORPORATING THE SAMERELATED APPLICATION DATA

[0001] This application is a nonprovisional of U.S. Provisional Patent Application Serial No. 63 / 540,816, filed on September 27, 2023, and titled “ICE-EJECTION MECHANISMS AND METHODS FOR ICEMAKERS, AND ICE MAKERS INCORPORATING THE SAME”, which is incorporated by reference herein in its entirety.FIELD

[0002] The present disclosure generally relates to the field of automated icemakers. In particular, the present disclosure is directed to ice-ejection mechanisms and methods for icemakers, and icemakers incorporating the same.BACKGROUND

[0003] Relatively large pieces of shaped ice (hereinafter “ice shapes”) have become popular for use in alcoholic drinks, especially “top-shelf’ whiskeys, tequilas, and vodkas, that drinkers desire to sip cold and savor. Not only are such ice shapes aesthetically pleasing in drink glasses, especially when they are completely clear, but they also minimize the amount of dilution of the alcohol that occurs before the drinker can finish the drink, allowing the drinker to continue to enjoy the taste of the alcohol longer than would occur in a drink containing smaller pieces of ice. This lower dilution results from the fact that a single large ice shape has less surface area for exposure to the alcohol than multiple pieces of smaller ice, and less surface area results in less melting ice that dilutes the drink.

[0004] Currently there is a dearth of automated icemakers that can produce relatively large ice shapes, particularly clear, i.e., noncloudy, ice shapes. Most large-ice-shape makers are manual devices that require a person to both fill the molds with water and remove the ice shapes from the molds by hand. Manually operated large-ice-shape makers are not only time consuming to fill and empty, but they also need an inordinate amount of human attention to ensure that the ice shapes are fully formed before emptying the molds.SUMMARY

[0005] In an implementation, the present disclosure is directed to an icemaker for making shaped ice. The icemaker includes a mold that, during icemaking operations, receives liquid water that freezes within the mold to make an ice shape, wherein the mold comprises a flexible wall; an ejection mechanism that includes: a pusher that, during ejection operations, pushes on the flexible wall of the mold so as to eject the ice shape from the mold; and a drive mechanism that, during the ejection operations, drives at least one of 1) the pusher and 2) at least a portion of the mold so that the pusher pushes on the flexible wall of the mold so as to eject the ice shape from the mold.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] For the purpose of illustration, the accompanying drawings show aspects of one or more embodiments of the disclosure. However, it should be understood that the scope of this disclosure is / are not limited to the precise arrangements and instrumentalities shown in the drawings, wherein:

[0007] FIG. 1 A is a top isometric view of an example split-mold icemaker made in accordance with aspects of the present disclosure, showing the icemaker as including four split molds arranged in two rows and fed water via a pair of water-recirculation systems;

[0008] FIG. IB is a reduced isometric exploded view of components of the icemaker of FIG. 1A;

[0009] FIG. 1C is an enlarged isometric exploded view of components of one of the drive mechanisms of the icemaker of FIG. 1A;

[0010] FIG. ID is a partial front elevational view / partial cross-sectional view of the icemaker of FIG. 1 A, showing each of the mold carriages in its closed state;

[0011] FIG. IE is a partial front elevational view / partial cross-sectional view of the icemaker of FIG. 1A, showing the lefthand mold carriage in its closed state and the righthand mold carriage in a partially open state;

[0012] FIG. IF is a partial front elevational view / partial cross-sectional view of the icemaker of FIG. 1A, showing the lefthand mold carriage in its closed state and the righthand mold carriage in a fully open state;

[0013] FIG. 1 G is a partial front elevational view / partial cross-sectional view of the icemaker of FIG. 1A, showing the lefthand mold carriage in its fully open state and the righthand mold carriage in its fully closed state;

[0014] FIG. 1H is an elevational view of an icemaker that is similar to the icemaker of FIG. 1 A except that it has only a single row of ice molds and pushers fixed to a wall of a freezer;

[0015] FIG. II is a reduced isometric exploded view of components of one of the two like water-recirculation systems of the icemaker of FIG. 1A;

[0016] FIG. 2A is a top perspective view of components of another example icemaker of the present disclosure having clamshell split molds, showing the mold halves of the split molds in an open position and engaged with corresponding respective pushers during ejection operations;

[0017] FIG. 2B is a front perspective view of the icemaker of FIG. 2A, showing the split molds in a closed state;

[0018] FIG. 3 is a top perspective view of internal components of a yet another example icemaker of the present disclosure having clamshell split molds in which each mold is mostly rigid but with a flexible- wall portion that engages a corresponding pusher during ejection operations;

[0019] FIG. 4 is a perspective elevational sideview of components of a further example icemaker of the present disclosure having split molds, showing the mold halves of the split molds in an open position with the mold halves moved axially apart from one another;

[0020] FIG. 5A is a perspective elevational view of an example self-closing ice mold of the present disclosure, showing the ice mold in a closed state;

[0021] FIG. 5B is another perspective elevational view of the self-closing ice mold of FIG. 5A in the closed state;

[0022] FIG. 5C is a perspective elevational view of the ice sphere made using the selfclosing ice mold of FIGS. 5A and 5B;

[0023] FIG. 5D is a perspective elevational view of the self-closing mold of FIGS. 5A and 5B and a drive mechanism, showing the drive mechanism pushing the ice sphere out of the selfclosing mold;

[0024] FIG. 6A is a perspective elevational view of another example self-closing ice mold of the present disclosure, showing the ice mold in a closed state;

[0025] FIG. 6B is another perspective elevational view of the self-closing ice mold of FIG. 6A in the closed state;

[0026] FIG. 6C is a perspective elevational view of the ice cube made using the self-closing ice mold of FIGS. 6A and 6B;

[0027] FIG. 6D is a perspective elevational view of the self-closing mold of FIGS. 6A and 6B and a drive mechanism, showing the drive mechanism pushing the ice cube out of the selfclosing mold;

[0028] FIG. 7 is a perspective elevational view of an example self-closing ice mold of the present disclosure having a self-closing seam bounded by a thickened rim;

[0029] FIG. 8 is a perspective elevational view of an example self-closing ice mold of the present disclosure having a pliable elastic portion and a rigid portion;

[0030] FIG. 9A is a perspective elevational view of a self-closing ice mold of the present disclosure having a self-closing seam that lies in a horizontal plane;

[0031] FIG. 9B is a perspective elevational view of a self-closing ice mold of the present disclosure having a self-closing seam that lies in a plane that is oriented 45° relative to horizontal and vertical planes;

[0032] FIG. 10A is a perspective elevational view of a self-closing mold of the present disclosure having a self-closing opening, showing the self-closing opening in a closed state;

[0033] FIG. 10B is a perspective elevational view of the self-closing mold of FIG. 10A, showing an ice sphere passing through the self-closing opening during ejection operations;

[0034] FIG. 11 is a partial perspective view / partial schematic diagram illustrating an example icemaker that includes a self-closing ice mold and a drive mechanism having a pusher that extends through a water reservoir;

[0035] FIG. 12 is a partial perspective view / partial schematic diagram illustrating another example icemaker that includes a self-closing ice mold and a drive mechanism having a pusher located outside of a water reservoir; and

[0036] FIG. 13 is a side elevational view of a self-closing ice mold held fixed by a support ring, showing the pusher of a drive mechanism pushing the ice sphere out of the ice mold.DETAILED DESCRIPTION

[0037] The entire contents of the appended claims are incorporated into this Detailed Description section by reference and should be treated as if originally presented herein.

[0038] Unless noted otherwise, the modifiers “first”, “second”, “third”, “fourth”, and the like, do not denote any particular order or importance, location, priority, etc. Rather, these modifiers are used simply to differentiate elements that are the same as or similar to one another in a set of two or more of such elements.

[0039] GENERAL

[0040] In some aspects, the present disclosure is directed to icemakers that make pieces of shaped ice (hereinafter, including in the appended claims “ice shapes”) in at least one mold and includes auto-ejection features that then automatically eject the ice shapes from the mold(s). Each ice shape may be of any suitable size, including sizes that are somewhat smaller than the inside diameter of a conventional whiskey tumbler so that only a single ice shape of the present disclosure will fit within the whiskey tumbler. Typically, an ice shape of the present disclosure is made of water, though other freezable liquids can be used, such as colored and / or flavored water, among others. For the sake of convenience, the term “water” will be used herein and in the appended claims for any suitable freezable liquid unless it is specifically noted that “water” should be construed literally. The shape of the ice shape may be any suitable shape, with spherical and cuboid being quite common, with any other shape that can be molded being possible. In an example, some embodiments of the icemakers of the present disclosure are configured to make ice spheres that each have a diameter in a range of 1.75 inches (4.45 cm) to about 2.5 inches (6.35 cm), though other embodiments can be configured to make ice spheres having diameters smaller than 1.75 inches or larger than 2.5 inches. In another example, the ice shapes may be true ice cubes (i.e., have six sides of identical area) having edge lengths in a range of 1.75 inches (4.45 cm) to about 2.5 inches. Many other shapes and sizes are possible.

[0041] An icemaker of the present disclosure includes at least one mold of any desired shape, such as any of the shapes noted above, that, during freezing operations, receives water inits liquid state and allows the water to freeze so as to create the ice shape that has the shape of the mold. In some embodiments, water is added to each mold when it is empty by causing it to flow into the mold, such as by opening a valve and allowing the water to flow into the mold by gravity or by force of pressure, such as from a pressurized domestic water line, among other ways. In an example, each mold is fed by a water-circulation system, such as a water-circulation system that gravity feeds water to the mold from a reservoir while simultaneously gently drawing water from the mold using a suction pump that returns the water to the reservoir. In some embodiments, each mold includes an upper end, and the water is both added to and withdrawn from the mold at such upper end. U.S. Patent Application Publication No. 2020 / 0370810 titled “METHODS OF PRODUCING CLEAR ICE SHAPES USING SUCTION, AND APPARATUSES FOR PERFORMING SAME”, published on November 26, 2020, in the names of Little et al. (hereinafter, “the ’810 publication”), discloses water circulation systems that can be used with the mold(s) of an icemaker made in accordance with the present disclosure. The ’810 publication is incorporated by reference herein for all of its teachings of making clear ice shapes, including manners of circulating water into and out of ice molds and causing the water to freeze directionally inside of the mold so as to maximize the clearness of the ice shape. An example icemaker 100 that incorporates clear-icemaking technology of the ’810 publication is described below relative to the accompanying FIGS. 1A through 1H.

[0042] In some embodiments, the auto-ejection features of an icemaker of the present disclosure includes one or more pushers and a drive mechanism that drives at least one of 1) at least a portion of each mold and 2) the pusher(s) in a manner that causes the pusher(s) to force the ice shape(s) out of the mold(s). In some embodiments, each mold has a flexible wall at least at a location where a pusher contacts the mold. In this manner, continued pushing of the pusher on the flexible wall at that location causes the pusher to force the ice shape out of the mold, with the flexible wall readily yielding and deforming by further movement of the pusher relative to the mold so as to ensure that the pusher fully disengages the ice shape from the mold. In some embodiments, each mold may be entirely made of a flexible material, such as a silicone rubber, neoprene rubber, etc., that has enough stiffness to maintain the shape of the mold but enough flexibility, at least at the location where the mold and the pusher engage one another, to allow the mold to yield and deform to effect the ejection. In some embodiments, some of each mold may be made of a relatively rigid material, such as plastic. In this context, the term “relatively rigidmaterial” is contrasted to a relatively flexible material in terms of its hardness and behavior as a structure of the mold. For example and in the context of structure of a mold, a rigid material would not yield to being pushed on by a pusher of the present disclosure without sustaining permanent damage, such as a plastic deformation (permanent), cracking, rupturing, etc., and any possible combination thereof. In contrast, a flexible material in the context of the mold and flexible wall thereof, is a material that will yield and elastically deform when being pushed on by a pusher of the present disclosure, as well as return to its pre-pushed shape when the pusher and the flexible wall are moved out of contact with one another.

[0043] In some embodiments, each mold may be a split mold having two halves that are sealingly engaged with one another when the mold is closed but that can be moved away from one another to open the mold. It is noted that the terms “halves”, “half’, and the like when used relative to a mold of the present disclosure do not necessarily require that each half defines 50% of the mold by any measure, such as internal volume or structure. Rather, unless noted otherwise, the terms “halves”, “half’, and the like when used relative to a mold of the present disclosure means that the two halves are movable relative to one another so as to open the mold. Such moveability can be a complete separation wherein the two halves are not physically joined to one another or a partial separation wherein the two halves are physically joined at an integrated hinge. In an example wherein the mold halves define differing percentages of the overall volume of the mold, one can envision that the inside of the mold defines a cylindrically shaped volume for forming an ice cylinder, and one mold half defines 70% of the cylindrically shaped volume while the other mold half defines 30% of the cylindrically shaped volume.

[0044] When a mold of the present disclosure is a split mold, the two halves of the mold may be moved apart from one another in any suitable way. For example, in some embodiments the mold halves may be moved away from one another in a clamshell manner, i.e., in a manner that involves pivoting one or both mold halves about a pivot axis at a wall of the mold along a mold-split plane that defines where the two mold halves separate from one another or beyond such a location outside the mold. As another example, in some embodiments the mold halves may be moved away from one another in a direction along a moment axis that is perpendicular to a mold-split plane that defines where the two mold halves separate from one another.

[0045] Tn some embodiments involving mold halves, one of the mold halves may be actively engaged by a pusher or may actively engage the pusher with the other mold half being passive relative to the ejection by pushing. As those skilled in the art can readily envision, in some embodiments it might be necessary / desirable to ensure that the ice shape release from the passive mold half before it releases from the active mold half to ensure that the ice shape never ends up being held by the passive mold half. In an example, the interior of the passive mold half may have a surface treatment different from the surface treatment of the active mold half to effect the difference. In an example, the passive mold half may include a heating element to raise the temperature of the passive mold half to effect the necessary ice-shape release. In an example, the locations and orientations of the passive and active mold halves may be such that gravity acting on the ice shape assists with 1) its disengagement with the passive mold half and 2) its remaining mold half engaged with the active mold half. In some embodiments, each mold half may be an active mold half, meaning that each mold half engages, and / or is engaged by, a corresponding pusher, respectively, by each mold half being driven into engagement with the corresponding pusher and the pusher being driven into engagement with the corresponding mold half.

[0046] In some embodiments, each mold half may be supported by a corresponding moldhalf support that couples that mold half to another part of the icemaker, such as a frame, a housing, and / or another structure of the icemaker. Each mold-half support may have any suitable form, such as a frame or a holder, among others. Depending on the location of the portion of the mold that engages, or is engaged by, the pusher, a mold-half support may include an opening through which the pusher extends temporarily during ejection operations. In some embodiments, each mold half may be removably installed into the corresponding mold-half support to allow a user to readily change-out the mold half, such as to install a differently shaped mold halve or replace a damaged mold half, among other things.

[0047] In some embodiments, a mold of an icemaker of the present disclosure may be a selfclosing mold that closes by itself after the ice shape has been forced out of the mold through a self-closing opening in the mold. Examples of such self-closing molds are illustrated in the appended FIGS. 5A-13 and described below in the “EXAMPLE EMBODIMENTS section. The ice shape may be ejected from the self-closing mold, for example, by driving the self-closingmold into engagement with a pusher or driving a pusher into engagement with the self-closing mold or a combination of both of these driving actions.

[0048] A drive mechanism for driving one, the other, or both of a mold, or portion thereof, and a pusher to effect ejection of an ice shape from the mold may take any suitable form. For example, the drive mechanism may include an electric rotary motor that drives, either directly or through a transmission, a linkage mechanism that is coupled to the relevant component(s) that the drive mechanism drives. The linkage mechanism, if provided, can be any suitable single or multilink mechanism that couples the rotary motor or transmission to the pusher or other component, such as a mold-half support. In an example, the linkage mechanism comprises a rack and pinon arrangement. In some embodiments, the drive mechanism may comprise one or more linear actuators (e.g., pneumatic, hydraulic, etc.). In some embodiments, a drive mechanism of the present disclosure may be a spring-biased mechanism that is held in tension or compression until ejection is desired. When ejection is desired, the spring-biased mechanism releases the tension or compression, for example, via a release trigger, to cause the pusher and / or mold, or portion thereof, to move so as to effect the ejection. After the ejection has been performed, the spring-biased mechanism and trigger are reset for the next ejection operations.

[0049] The foregoing and other embodiments and features are exemplified in the following section.

[0050] EXAMPLE EMBODIMENTS

[0051] With the foregoing in mind, this section describes some example embodiments that combine various features, elements, and components discussed above. These examples are not intended to cover all possible combinations and permutations of the features, elements, and components discussed above. Rather, they are simply illustrative of manners in which the foregoing features, elements, and components can be combined with one another and results that can be achieved therefrom.

[0052] Split-Mold Examples

[0053] In some embodiments, icemakers of the present disclosure include one or more split molds that allow the corresponding ice shape(s) to be ejected from the mold(s) after the mold halves of the mold(s) are separated from one another or while the mold halves are beingseparated from one another. In some embodiments, movement of each of the mold halves effects ejection of the ice shape from the mold part with which the ice shape remains engaged after separating the mold halves. In some embodiments, icemakers of this disclosure can be used with clear-icemaking techniques disclosed in the ’810 publication mentioned in the GENERAL section above. Examples of icemakers and components thereof made in accordance with the present disclosure are illustrated in FIGS. 1A through 4, which are described in detail immediately below.

[0054] Referring now to the drawings, FIGS. 1 A and IB illustrate an example split-mold icemaker 100 made in accordance with aspects of the present disclosure. In this example, the icemaker 100 includes four split spherical molds 104(1) through 104(4) (only one mold fully visible in FIG. IB) for making ice spheres (not shown, but see, e.g., ice sphere 212 of FIG. 2A), and the molds are arranged in first and second rows 104R(l) and 104R(2) of two molds each. The ones of the molds 104(1) through 104(4) in each of the two rows 104R(l) and 104R(2) is supported in a corresponding first and second mold carriage 108(1) and 108(2) that is opened and closed in a clamshell-like manner, as best seen in FIG. IB, with the second mold carriage 108(2) shown in an open state. In FIG. IB, the first mold carriage 108(1) is shown in its closed state.

[0055] Each of the molds 104(1) through 104(4) includes first and second mold halves 104H(l) and 104H(2) (FIG. IB), and each of the first and second mold carriages 108(1) and 108(2) includes a first mold-half support 112(1) and a second mold-half support 112(2) that supports corresponding ones of the first and second mold halves. In this example, the first and second mold-half supports 112(1) and 112(2) of each of the first and second mold carriages 108(1) and 108(2) are joined to one another via hinges 116, and each of the first mold-half supports 112(1) is pivotable about the corresponding hinges relative to the second mold-half supports 112(2), which are fixed so that the first and second mold carriages open and close in a clamshell-like manner. In this example each of the first and second mold-half supports 112(1) and 112(2) has a frame-like structure.

[0056] In this example, the icemaker 100 includes first and second drive mechanisms 120(1) and 120(2) that drive corresponding ones of the first mold-half supports 112(1) to effect theopening and closing of the first and second mold carriages 108(1) and 108(2). In the embodiment shown, each drive mechanism 120(1), 120(2) includes an actuator 124 and a linkage mechanism 128 that couples the corresponding one of the first mold-half support 112(1) with the actuator. Referring to FIG. 1C, each linkage mechanism 128 includes a driven arm 128D and an idler arm 1281 that are connected by a link bar 128L. Each actuator 124 includes a motor 124M and a transmission 124T, with the transmission being linked to the driven arm 128D of the corresponding mold-half support 112(1) by a coupler 124C that is supported at one end by a pivot mount 124P. The motor 124M and the transmission 124T are mounted to a support bracket 124B composed of first and second parts 124B(1) and 124B(2).

[0057] Referring now to FIG. ID, this figure shows both of the first and second mold carriages 108(1) and 108(2) in their closed states in which all four molds 104(1) through 104(4) are closed. In the embodiment shown, each of the second mold-half supports 112(2) of each of the first and second drive mold carriages 108(1) and 108(2) includes a pusher 132 that is located generally opposite from and acts upon a corresponding mold half 104H(l) of the respective mold 104(1) to 104(4) as described below in detail in connection with FIGS. ID to 1G. As also seen in FIG. ID, each mold half 104H(l) and 104H(2) is removably engaged with the corresponding one of the mold-half supports 112(1) and 112(2) using an arrangement that includes thumb screws 136 for securing and releasing the corresponding mold half. Also seen in FIG. ID are coaxial feed and suction passageways 140 and 144, respectively, at the top of the mold 104(3) that are part of a second water-recirculation system 148(2) that is described in more detail below.

[0058] FIG. IE shows the second mold carriage 108(2) in a partially open state after the second drive mechanism 120(2) (FIG. 1C) has driven the first mold-half support 112(1) away from the second mold-half support 112(2) that remain fixed relative to the rest of the icemaker 100. Although not shown, the presence of an ice sphere can be readily envisioned to be located in the mold 104(3) and particularly seated in the first mold half 104H(l) as the second drive mechanism 120(2) moves the first mold half away from the second mold half 104H(2). As noted above, to ensure that the ice sphere remains in the first mold half 104H(l) during opening of the mold 104(3), the second mold half 104H(2) may, for example, be heated and / or have a special surface treatment that assists in the release of the ice sphere.

[0059] FIG. IF shows the second mold carriage 108(2) in a fully open, ice-ejection state after the second drive mechanism 120(2) (FIG. 1 C) has driven the first mold-half support 112(1) of the second mold carriage away from the corresponding second mold-half support 112(2) of the second mold carriage. As FIG. IF illustrates, when the second mold carriage 108(2) is in this fully open state, the pusher 132 on the opposite first mold carriage 108(1) extends through the first mold-half support 112(1) of the second mold carriage and pushes on the flexible wall of the mold half 104H(l) of the mold 104(3), causing the flexible wall to flex inward relative to the mold and thereby push the ice sphere (not shown) out of the mold half 104H(l). Although not shown, it can be readily envisioned that the ejected ice sphere can readily fall from the mold 104(3) under the influence of gravity, such as into a collection bin (not shown) below the icemaker 100.

[0060] FIG. 1G shows the first mold carriage 108(1) in a fully open, ice-ejection state after the first drive mechanism 120(1) (FIG. 1 A) has driven the first mold-half support 112(1) of the first mold carriage away from the corresponding second mold-half support 112(2) of the first mold carriage. As FIG. 1G illustrates, when the first mold carriage 108(1) is in this fully open state, the pusher 132 on the opposite second mold carriage 108(2) extends through the first moldhalf support 112(1) of the first mold carriage and pushes on the flexible wall of the mold half 104H(l) of the mold 104(1), causing the flexible wall to flex inward relative to the mold and thereby push the ice sphere (not shown) out of the mold half 104H(l). Although not shown, it can be readily envisioned that the ejected ice sphere can readily fall from the mold 104(1) under the influence of gravity, such as into a collection bin (not shown) below the icemaker 100.

[0061] FIG. 1H shows an icemaker 100' that is largely the same as the icemaker 100 except that it has only one row 104R' containing molds 104' and the corresponding pushers 132' are mounted to a wall 150W of a freezer 150. The icemaker 100' of FIG. 1H can be useful, for example, where space for an icemaker of the present disclosure is limited or it otherwise fits in well with a particular freezer design or configuration. As those skilled in the art will readily appreciate, the row 104R' may have any number of molds 104' suitable for the particular application at issue. For example, the row 104R' may have 2 molds 104', 3 molds, 4 molds, etc., with the number of molds in the row being limited, at its maximum, by the length (here, into thesheet of FIG. 1H) of the wall 150W. All other aspects and features of the icemaker 100' may be the same as or similar to the like aspects and features of the icemaker 100 of FIG. 1A.

[0062] FIG. II shows components of the second water-recirculation system 148(2) of the icemaker 100 of FIG. 1A. As seen in FIG. 1A, the icemaker 100 has two like water-recirculation systems 148(1) and 148(2) that serve the molds 104(1) through 104(4) of the respective first and second mold carriages 108(1) and 108(2). Each of the first and second water-recirculation systems 148(1) and 148(2) incorporate the principles of clear icemaking as discussed in the ’810 publication incorporated herein by reference above. For a full understanding of the operating principles of the first and second water-recirculation system, the reader should read the ’810 publication.

[0063] Referring to FIG. II, the second water-recirculation system 148(2) includes a reservoir 148R for holding the water (not shown) that fills the corresponding molds 104(3) and 104(4) (not shown in FIG. II) and that the second water-recirculation system recirculates into the molds during freezing operations. The reservoir 148R has first and second pairs 152(1) and 152(2) of coaxial fittings that each include a feed fitting 152F that feeds water from the reservoir to the corresponding mold 104(3), 104(4) and a suction fitting 152S that suctions water out of the corresponding mold. Each pair 152(1) and 152(2) of coaxial fittings fluidly couples to the respective feed and suction passageways, with FIG. ID illustrating such feed and suction passageways 140 and 144, respectively for the mold 104(3).

[0064] With continuing reference to FIG. II, the icemaker 100 (FIG. 1A) of this example is designed and configured to reside within a freezer (not shown). Consequently, the reservoir 148R is temperature controlled to prevent the water in the reservoir from freezing while also optimizing the freeze time of the ice spheres that the icemaker (FIG. 1 A) makes. In this example, such temperature control is accomplished using an insulated housing 148H and heating coils (not shown) that wrap around the reservoir and are held in place via ribs 156 on the outside wall of the reservoir.

[0065] The second water-recirculation system 148(2) includes a suction pump 148P and corresponding plumbing, which includes intake piping 1601 that draws water from the molds 104(3) and 104(4) (not shown in FIG. II) and return piping 160R that returns water fromthe molds to the reservoir 148R. The insulated housing 148H includes An insulated lid 148L, and the suction pump 148P, the intake piping 1601, and the return piping 160R are held by a support structure 164 that includes a top shell 164T and a bottom shell 164B.

[0066] FIGS. 2A and 2B illustrate components of another example split-mold icemaker 200 made in accordance with aspects of the present disclosure. In this example, the icemaker includes a single clamshell-like mold carriage 204 having four internally spherical molds 208(1) through 208(4) for making four ice spheres (one ice sphere 212 shown) in each freezing cycle. The mold carriage 204 includes first and second mold-half supports 204(1) and 204(2) that are joined at hinges 216 and are moved apart from one another via a driving mechanism 220, here, including an electric motor 220M and a linkage mechanism 220L, that move both of the first and second mold-half supports away from one another. Each of the molds 208(1) through 208(4) includes first and second mold halves 208H(l) and 208H(2) made of a pliable, flexible material, such as any of such materials noted elsewhere in this disclosure. FIGS. 2A and 2B show, respectively, the mold carriage 204 in an open, ejection state and in a closed, icemaking state.

[0067] The icemaker 200 includes eight pushers 224(1) through 224(8) that are fixed and that correspond to respective ones of the first and second mold halves 208H(l) and 208H(2) of the four molds 208(1) through 208(4) that engage during ejection operations and when the mold carriage 204 is in the open state shown in FIG. 2 A. In this example, a pusher 224(1) through 224(8) is provided for each mold half 208H(l) and 208H(2) of each mold 208(1) through 208(4) to account for the fact that, upon opening of the mold carriage 204, the corresponding ice sphere, such as ice sphere 212, could remain engaged with either of the halves depending on which mold half the ice sphere releases from first. Upon ejection of the ice spheres, such as ice sphere 212, from the molds 208(1) through 208(4) under action of the corresponding pushers 224(1) through 224(8), they fall into a collection bin 228. FIG. 2B shows the icemaking components of FIG. 2A enclosed in a freezer 232 dedicated to making the ice spheres, such as the ice sphere 212. The freezer 232 may be, for example, a countertop freezer or a built-in type freezer. In other embodiments, the freezer 232 may not be a freezer dedicated to making ice spheres. For example, the freezer 232 may be part of a domestic or commercial freezer for keeping other products frozen. These example freezer environments of the icemaker 200 are equally applicable to all other icemakers disclosed in this disclosure.

[0068] FIG. 3 illustrates an example icemaker 300 that is largely the same as the icemaker 200 of FIGS. 2A and 2B. The primary difference between these icemakers is that the molds 208(1) through 208(4) of the icemaker 200 of FIGS. 2A and 2B are made entirely of a pliable flexible material, whereas the molds 304(1) through 304(4) are made of a rigid material, such as a hard thermoplastic, except at the corresponding locations 304L(l) through 304L(8) (only four such locations seen in FIG. 3; four like locations are also present on the obscured side of the mold carriage 308). Each of the locations 304L(l) through 304L(8) comprises a pliable flexible material (e.g., any such material noted elsewhere herein) that allows the corresponding pusher (not shown, but see the pushers 224(1) through 224(8) of FIG. 2A) to deform that portion of the mold so as to effect the ejection of any ice sphere, such as the ice sphere 212 shown) from the corresponding mold 304(1) through 304(4). All other features and aspects of the icemaker 300 of FIG. 3 may be the same as or similar to the icemaker 200 of FIGS. 2A and 2B.

[0069] FIG. 4 shows another example split-mold icemaker 400 that, instead of providing clamshell-like opening and closing of the mold carriage like the examples of FIGS. 1A through 3, provides a linear opening and closing of the mold carriage 404. To effect these linear operations, the icemaker includes a drive mechanism 408, and the mold carriage 404 includes first and second mold-half supports 412(1) and 412(2) and a pair of linear guides 416 that allow the drive mechanism to move the second mold-half support linearly away from the first moldhalf support. In this example, the drive mechanism 408 includes a linear motor 408M and a linkage mechanism 408L to drive the opening and closing of the mold carriage 404 and the corresponding mold 420.

[0070] The mold 420 in this example is a multi-chamber mold having a plurality of like rectilinear chambers 420C (only some labeled to prevent cluttering the figure) for forming a corresponding plurality ice cuboids (not shown). The mold 420 includes two mold halves 420H(l) and 420H(2) that are mounted in two corresponding cartridges 424(1) and 424(2) that are removably secured to corresponding ones of the first and second mold-half supports 412(1) and 412(2). Each of the mold halves 420H(l) and 420H(2) is made entirely of a pliable flexible material, such as any of such materials noted elsewhere in this disclosure.

[0071] The icemaker 400 includes a plurality of pushers 428 that are fixed relative to the moveable second mold-half support 412(2) so that when the drive mechanism 408 opens the mold carriage 404 for ice ejection, it drives the second mold half 420H(2) into the pushers, which cause the second mold half to deform and, as a result, release the ice cuboids (not shown), here into a collection bin 432 located below the mold carriage 404. It is noted that in this example, the pushers 428 are not arranged and individualized to act upon the individual mold chambers 420C. Rather, the pushers 428 act upon the entire multi-chamber second mold half 420H(2) to effect the ejection. It is noted that in alternative embodiments, the pushers 428 need not be fixed relative to the moveable second mold-half 420H(2). Rather, they may be attached to the second mold-half support 412(2) and / or to the second mold half 420H(2) so as to move therewith. In such embodiments, the drive system 408 would move the second mold-half support 412(2) and the pushers 428 so that the pusher contacts a fixed structure, e.g., a wall 436W of a freezer 436, so as to cause the pushers to push against the second mold half 420H(2) and cause the ejection of the ice cuboids. In other embodiments, the pushers 428 may be driven to effect the ice ejection, either alternatively to the opening of the mold carriage 404 or in conjunction with the opening of the mold carriage. These variations of pusher attachment locations and pusher driving are equally applicable to any other icemaker disclosed in this disclosure.

[0072] Self-Closing-Mold Examples

[0073] In some embodiments, an icemaker of the present disclosure may include a mold type that is at least partially formed by a highly elastic, pliable material and includes a seam or other self-closing opening that opens when the pusher of a drive mechanism pushes on the ice shape inside the mold such that it causes the self-closing opening to open or stretch wide enough to release the ice shape. Examples of such highly elastic material include, but are not limited to, silicone rubber, natural rubber, nitrile rubber, neoprene rubber, and / or polyurethane rubber, among others. After the ice shape has been pushed out of the mold, the mold self-closes by the configuration of the mold itself and / or in conjunction with one or more close-assisters.Examples of close-assisters include, but are not limited to, magnets and spring-steel bars, among others. Example self-closing molds are described below.

[0074] FIGS. 5A-5D illustrate an example self-closing mold 500 that makes an ice sphere 504. In this example, the self-closing mold 500 is made of a highly elastic, pliable material and has a self-closing opening 508, here, a meridional seam, and a corresponding pair of flanges 512(1) and 512(2) that each hold a set 516(1) and 516(2) of magnets that attract one another so as to close the self-closing opening. As seen in FIG. 5D, the ice sphere 504 is ejected from the self-closing mold 500 via a drive mechanism 520 that includes a linear actuator 524 and a pusher 528. The pressure of the pusher 528 pushing on the ice sphere 504 naturally releases the magnetic hold of the sets 516(1) and 516(2) of magnets along the meridional seam 508 and opens up the mold 500 to allow the ice sphere to drop freely out of the mold by gravity. The mold 500 then naturally returns to its original state via its elastic properties and the sets 516(1) and 516(2) of magnets attract one another to close the meridional seam 508 to ensure a watertight seal.

[0075] FIGS. 6A-6D show an example self-closing mold 600 similar to the self-closing mold of FIGS. 5A-5D except that it is configured to make an ice cube 604 (FIGS. 6C and 6D) and includes a pair of seams 608(1) and 608(2) that cross one another on diagonals on one face of the self-closing mold. Each of the seams 608(1) and 608(2) is flanked by corresponding pairs of flanges 612(1) & 612(2) and 612(3) & 612(4) having corresponding sets 616(1) & 616(2) and 616(3) & 616(4) of magnets that attract one another to hold the seams closed and, after opening, returning the seams to their closed states. FIG. 6D shows the ice cube 604 being pushed out of the self-closing mold 600 by a drive mechanism 620 that includes a linear actuator 624 and a pusher 628. The pressure of the pusher 628 pushing on the ice cube 604 naturally releases the magnetic hold of the sets 616(1) & 616(2) and 616(3) & 616(4) of magnets along the seams 608(1) and 608(2) and opens up the mold 600 to allow the ice cube to drop freely out of the mold by gravity. The mold 600 then naturally returns to its original state via its elastic properties and the sets 616(1) & 616(2) and 616(3) & 616(4) of magnets attracting one another close the seams 608(1) and 608(2) to ensure a watertight seal.

[0076] In alternative embodiments of the self-closing molds 500 and 600 of FIGS. 5A-5D and 6A-6D, respectively, the molds may include continuous magnets along each seam 508 and 608(1) and 608(2) or a series of multiple smaller magnets that are adequately spaced to ensure that they are attracted to their appropriate mate so that the respective mold returns to itsoriginal state. The magnets would be oriented such that one side of the seam of the mold would have a magnet(s) paired with a magnet(s) of the opposite pole on the other side of the seam to ensure magnetic attraction. In other embodiments, pairs of magnets on opposing seams can be replaced by pairs that each contain a magnet and a magnetically attracted body.

[0077] FIG. 7 illustrates another example self-closing mold 700 made of a pliable elastic material, wherein the self-closing seam 704 incorporates close assisters (not seen), such as a pair of elongate spring-steel curved members or other more-rigid but elastic material component, embedded in a thickened rim 708 of the seam 704 of the mold 700 that is designed to open when the force of an ice shape is pressed against it and after the ice falls out it would return to its original state via the elastic action of the rigid component and “self-close.” In another embodiment, the thickened rim 708 need not include the additional rigid elastic component if it is designed to have the requisite self-closing ability, as those skilled in the art will readily appreciate.

[0078] FIG. 8 shows another embodiment of a self-closing mold 800 that is similar to the self-closing mold 500 of FIGS. 5A-5D but includes both a pliable elastic portion 804 and a rigid portion 808. Aspects of the pliable elastic portion 804 may be the same as or similar to the like aspects of the self-closing mold 500 of FIGS. 5A-5D.

[0079] While FIGS. 5A-5D and 7 show, respectively, self-closing molds 500 and 700 in which the self-closing seams 508 and 712 are located in a vertical plane (not shown), FIGS. 9A and 9B illustrate that the self-closing seams can be located otherwise. For example, FIG. 9A shows a self-closing mold 900 having a self-closing seam 904 located in a horizontal plane, and FIG. 9B shows a self-closing mold 920 having a self-closing seam 924 located on a 45° angle relative to vertical and horizontal planes (not shown). Other orientations of self-closing seems can be used.

[0080] FIGS. 10A and 10B illustrate an example self-closing mold 1000 that makes an ice sphere 1004 and is made of a highly flexible and pliable material that the self-closing opening 1008 is an openable hole. Not seen is a drive mechanism, which can be the same as or similar to any suitable one of the drive mechanisms shown and / or described in this disclosure.

[0081] FIGS. 11-13 illustrate examples of how drive mechanisms, here, drive mechanisms 1100, 1200, and 1300, can effect ejection of the corresponding ice shapes, here, ice shapes 1104, 1204, and 1304, from the respective self-closing molds 1108, 1208, and 1308. In FIG. 11, an actuator 1112 of the drive mechanism 1100 can drive a single or multiprong pusher 1116 to push the ice shape 1104 out of the mold 1108 and may run through one or more sealed conduit(s) 1120 above the mold to operate inside of a water reservoir 1124 directly above the mold and to ensure they do not leak. As noted in the GENERAL section above, there are many different potential options for the actuator 1112, including, but not limited to, linear actuators, basic gear systems, worm-screw systems, etc. The actuator 1112 could also be designed to seal off the mold 1108 from the water reservoir 1124 during ejection operations such that while the ice is being pushed out of the mold, no water 1128 is able to leak out until the drive mechanism 1100 has completed its ejection cycle. Although not illustrated, one way for this to be achieved would be to have the pusher 1116 pass through a center top fill hole of the mold 1108, and the pusher would be larger than the hole to provide a friction seal once it passes through. See, for example, the ’810 publication for examples of designs that include a center top fill hole. Alternatively and as shown in FIG. 12, the pusher 1212 of the drive mechanism 1200 can run externally to the water reservoir 1220 either at a completely vertical or angled orientation. In the arrangement of FIG. 12, the actuator 1216 may drive the pusher 1212 to push on the flexible wall of the self-closing mold 1208.

[0082] In FIG. 13, the mold 1308, which includes a horizontal self-closing seam 1312, is supported by a meridional support ring 1316 that is secured to a fixed structure 1320 that holds the ring fixed at all times. When it is time to eject the ice shape 1304, the actuator 1324 of the drive mechanism 1300 pushes the pusher 1328 against the flexible wall of the mold 1308 at the equator so as to push the ice shape out through the self-closing seam 1312. In some embodiments, the pusher 1328 can be attached to the side wall of the mold 1308 to pull the mold wall back to its original position after the ice shape 1304 has been pushed out, for example if the flexible wall needs to go so far that it cannot pop-back on its own.

[0083] The drive mechanism 1300 must displace a significant amount of the volume of the ice shape 1304 inside the mold 1308 to ensure that the self-closing seam 1312 is forced open wide enough for the ice shape to drop freely out of the mold. Generally, the amount of suchvolume that needs to be displaced is determined by the size and shape of the ice shape 1304, but in some embodiments could be at least 50% of the inner width of the mold. The force can be applied inside of the ice mold or outside of the ice mold and from any direction, including but not limited to, the top, the bottom, the side, or another angle.

[0084] The ejection operations of the drive mechanism 1300 can be manually or electronically initiated. In an electronic version, a set action, such as an action triggered by a timer or one or more sensors, could initiate the drive mechanism 1300 to cycle and eject the ice shape 1304 from the mold 1308. It could also be manually initiated by an end user when she / he visibly sees that the ice shape 1304 is ready to be ejected. The actuator 1324 could also be manually or electronically operated. In an electronic version, the actuator 1324 may be an electrically powered device that drives the pusher 1328. In a manually operated version (not shown), the end user could, for example, turn a wheel or crank of some kind or push a plunger or a lever to drive the pusher 1328. These principles can be applied to other drive mechanisms disclosed herein, as those skilled in the art will readily appreciate. It is noted that in alternative embodiments the fixed and movable natures of, respectively, the mold 1308 and the pusher 1328 may be reversed. That is, in such embodiments the pusher 1328 may be held fixed by the fixed structure 1320 and the support ring 1316 may be moveable relative to the pusher so that the selfclosing mold 1308 is pushed into the pusher so as to effect the ejection of the ice shape 1304.

[0085] Various modifications and additions can be made without departing from the spirit and scope of this disclosure. Features of each of the various embodiments described above may be combined with features of other described embodiments as appropriate in order to provide a multiplicity of feature combinations in associated new embodiments. Furthermore, while the foregoing describes a number of separate embodiments, what has been described herein is merely illustrative of the application of the principles of the present invention. Additionally, although particular methods herein may be illustrated and / or described as being performed in a specific order, the ordering is highly variable within ordinary skill to achieve aspects of the present disclosure. Accordingly, this description is meant to be taken only by way of example, and not to otherwise limit the scope of this invention.

[0086] Exemplary embodiments have been disclosed above and illustrated in the accompanying drawings. It will be understood by those skilled in the art that various changes, omissions and additions may be made to that which is specifically disclosed herein without departing from the spirit and scope of the present invention.

Claims

What is claimed is:

1. An icemaker for making shaped ice, the icemaker comprising: a mold that, during icemaking operations, receives liquid water that freezes within the mold to make an ice shape, wherein the mold comprises a flexible wall; an ejection mechanism that includes: a pusher that, during ejection operations, pushes on the flexible wall of the mold so as to eject the ice shape from the mold; and a drive mechanism that, during the ejection operations, drives at least one of 1) the pusher and 2) at least a portion of the mold so that the pusher pushes on the flexible wall of the mold so as to eject the ice shape from the mold.

2. The icemaker of claim 1, wherein, during the ejection operations, the pusher remains fixed, and the drive mechanism drives the flexible wall of the mold into engagement with the pusher.

3. The icemaker of claim 2, wherein the mold comprises two halves, and, during the ejection operations, the drive mechanism separates the two halves to open the mold and drives one of the two halves so that the flexible wall of the mold engages the pusher.

4. The icemaker of claim 3, wherein the icemaker comprises first and second mold-half supports that support respective ones of the two halves of the mold, and the drive mechanism connects to the first mold-half support so as to move the first mold-half and the corresponding one of the mold halves.

5. The icemaker of claim 4, wherein the first and second mold-half supports are arranged and supports so as to provide clamshell opening and closing.

6. The icemaker of either one of claims 4 and 5, wherein the drive mechanism comprises a rotational motor and mechanical link system coupled between the rotational motor and the first mold-half support.

7. The icemaker of either one of claims 4 and 5, wherein the first mold-half support includes an opening, and, during the ejection operations, the pusher extends through the opening so as to engage the flexible wall.

8. The icemaker of claim 4, wherein each of the first and second mold halves is removably engaged with the corresponding one of the first and second mold-half supports so as to be readily replaceable.

9. The icemaker of claim 8, wherein each of the first and second mold halves is made of a flexible material.

10. The icemaker of claim 9, wherein the flexible material is silicone rubber.

11. The icemaker of any one of claims 4, 5, and 8-10, wherein, when the mold is closed, the first and second mold halves engage one another in a mold-split plane that, during the freezing operations, forms a mold-split angle of greater than 0° with a horizontal plane.

12. The icemaker of claim 11, wherein the mold-split angle is in a range of 30° to 60°.

13. The icemaker of any one of claims 1-5 and 8-10, wherein the icemaker is a clear-ice icemaker and further comprises a water-circulation system that circulates the water into the mold via gravity feed and out of the mold via suction.

14. The icemaker of claim 13, wherein, during the freezing operations, the mold has an upper end, and the gravity feed and suction each occur at the upper end of the mold.

15. The icemaker of claim 14, wherein, during the freezing operation, the suction is applied at a central location and the gravity feed occurs radially outward of the central location.

16. The icemaker of claim 13, wherein the water-circulation system comprises a water reservoir located above the mold.

17. The icemaker of claim 16, wherein the water reservoir is temperature controlled as a function of freezing time for the ice shape.

18. The icemaker of claim 1, wherein: the mold is a first split mold having first and second mold halves; the ice shape is a first ice shape; the flexible wall is a first flexible wall of the first mold half of the first split mold; the drive mechanism is a first drive mechanism; and the pusher is a first pusher; the icemaker further comprising: a second pusher; a second split mold having third and fourth mold halves that, during the icemaking operations receives water that freezes to make a second ice shape, wherein the third mold half comprises a second flexible wall; a first clamshell mold support having first and second mold-half supports that support, respectively, the first and second mold halves of the first split mold; a second clamshell mold support having third and fourth mold-half supports that support, respectively, the third and fourth mold halves; and a second drive mechanism operatively coupled to the third mold-half support that, during the ejection operations, opens the second clamshell mold so that the second flexible wall engages the second pusher and the second pusher ejects the second ice shape from the third mold half; wherein the first drive mechanism is operatively coupled to the first mold-half support so that, during the ejection operations, the first drive mechanism opens the first clamshell mold such that the first flexible wall engages the first pusher and the first pusher ejects the first ice shape from the first mold half.

19. The icemaker of claim 18, wherein the first pusher is part of the third mold-half support of the second clamshell mold support, and the second pusher is part of the first mold-half support of the first clamshell mold support.

20. The icemaker of claim 18, wherein each of the first and second drive mechanisms comprises a rotational motor and mechanical link system coupled between the rotational motor and the first mold-half support.21 . The icemaker of claim 18, wherein each of the first and third mold-half supports includes an opening, and, during the ejection operations, the first pusher extends through the opening in the first mold-half support so as to engage the first flexible wall of the first mold and the second pusher extends through the opening in the third mold-half support so as to engage the second flexible wall of the second mold.

22. The icemaker of claim 21, wherein each of the first and second mold halves is removably engaged with the corresponding one of the first and second mold-half supports so as to be readily replaceable.

23. The icemaker of claim 22, wherein each of the first and second mold halves is made of a flexible material.

24. The icemaker of claim 23, wherein the flexible material is silicone rubber.

25. The icemaker of any one of claims 18-24, wherein: when the first mold is closed, the first and second mold halves engage one another in a first mold-split plane that, during the freezing operations, forms a first mold-split angle of greater than 0° with a horizontal plane; and when the second mold is closed, the third and fourth mold halves engage one another in a second mold-split plane that, during the freezing operations, forms a second mold-split angle of greater than 0° with the horizontal plane.

26. The icemaker of claim 25, wherein each of the first and second mold-split angles is in a range of 30° to 60°.

27. The icemaker of claim 26, wherein, when both of the first and second molds are closed, the first and second mold-split planes form a combined angle that is the sum of the first and second mold-split angles.

28. The icemaker of any one of claims 18-27, wherein the icemaker is a clear-ice icemaker and further comprises a water-circulation system that circulates the water into the first and second molds via gravity feed and out of the mold via suction.

29. The icemaker of claim 28, wherein, during the freezing operations, the first mold has a first upper end, the second mold has a second upper end, and the gravity feed and suction each occur at each of the first and second upper ends of the respective first and second molds.

30. The icemaker of claim 29, wherein, during the freezing operation, the suction is applied at a central location at each of the first and second upper ends and the gravity feed occurs radially outward of the central location at each of the first and second upper ends.

31. The icemaker of claim 28, wherein the water-circulation system comprises a first water reservoir located above the first mold, and a second water reservoir located above the second mold.

32. The icemaker of claim 31, wherein each of the first and second water reservoirs is temperature controlled as a function of freezing time for, respectively, the first and second ice shapes.

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