Clear Ice Freezing Module With Water Circulation and Demolding
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Solution Overview
Problem
Current systems for manufacturing clear ice are time-consuming, wasteful, and labor-intensive, with slow freezing processes that can take several days and require manual handling, leading to inefficiencies and safety concerns.
Innovation Solution
A system comprising a freezing module with plate freezers, circulation pumps, and a demolding module that automates the process of forming clear ice sheets, allowing for rapid freezing and safe removal of ice without the need for manual handling or specialized expertise, using a frame with movable control frames and pumps to circulate water and release air bubbles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If slow freezing with constant circulation is used to remove air bubbles, then clear ice is produced, but the manufacturing time increases to several days
Solution Approach 1:
The system performs preliminary actions by pre-chilling the mold and water before the freezing process begins. The mold is cooled to sub-freezing temperatures in advance, and water is deaerated beforehand, which accelerates the subsequent freezing process while maintaining ice clarity.
Solution Approach 2:
The invention changes the temperature parameters dynamically during the freezing process. The mold temperature is maintained at sub-freezing levels (-10°C to -20°C) rather than standard freezing temperatures, and the water circulation rate is adjusted throughout the process to optimize both speed and clarity.
2Ease of manufacture
If manual handling and specialized expertise are required for ice removal, then ice can be extracted, but labor intensity and safety risks increase
Solution Approach 1:
The system performs self-service by automatically removing ice from the mold using a heated wire or blade that traverses the mold cavity. The ice is ejected or separated automatically without requiring manual intervention, making the system safe for unskilled operators.
Solution Approach 2:
The invention replaces manual mechanical handling with an automated demolding mechanism. A heated wire or electric blade cuts the ice from the mold automatically, substituting dangerous manual labor with a controlled mechanical system that requires no specialized expertise.
3Object-affected harmful factors
If disposable liners are used in galvanized steel chambers, then food safety is ensured, but waste increases and device complexity increases
Solution Approach 1:
The system uses disposable food-safe liners made from inexpensive materials like plastic or parchment paper. These liners are discarded after single use, ensuring food safety without requiring complex cleaning or sterilization procedures, and the low cost minimizes waste impact.
Solution Approach 2:
The invention uses thin film liners that conform to the mold cavity shape, providing a food-safe barrier between the ice and the galvanized steel chamber. These flexible thin films are easy to install and remove, ensuring safety while minimizing material usage.
4Manufacturing precision
If constant single speed circulation is used, then air bubbles are removed, but energy consumption increases and process efficiency decreases
Solution Approach 1:
The system transitions from constant single-speed circulation to dynamic variable-speed circulation. The pump speed is adjusted throughout the freezing process, operating at higher speeds during initial air bubble removal and reducing speed as freezing progresses, optimizing both ice clarity and energy efficiency.
Solution Approach 2:
The invention implements periodic circulation rather than continuous constant-speed operation. The pump operates in cycles with varying intensities, providing strong circulation during critical phases for bubble removal and reducing or pausing circulation during stable freezing phases, thereby reducing overall energy consumption.
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 system enables the rapid and efficient production of clear, dense ice with minimal waste and labor, ensuring food safety and reducing the risk of injury, while producing ice products with minimal imperfections and consistent thickness.
Implementation Method 1
One or more circulation pumps are associated with each control frame, wherein the circulation pumps circulate water in the mold to release air bubbles as the water freezes
Implementation Method 2
a freezing module for creating clear ice sheets... a plate freezer provided at each level
Implementation Method 3
The cooling unit 12 includes a refrigerant and refrigeration system
Data Source
AI summary
A system for manufacturing clear ice products is provided. The system includes a freezing module, a demolding module, and a converting station. The freezing module includes a frame comprising a plurality of levels, a plate freezer provided at each level, and at least one mold provided for placement on each plate freezer and suitable for receiving water. A control frame is provided associated with each plate freezer and is movable from an elevated position to fill position. In the fill position, the control frame is at least partially disposed within the mold. One or more circulation pumps are associated with each control frame for circulating water in the mold to release air bubbles as the water freezes. The demolding module removes the mold from the freezing module and removes formed ice from the mold. The converting station converts the formed ice into a clear ice product.