Clear Ice Sheet Fusion for Faster Spherical Ice Molding
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Solution Overview
Problem
Forming a clear ice block of sufficient thickness for molding ice structures is time-consuming, as the water-ice freezing surface moves further away from the cooling source, reducing freezing efficiency.
Innovation Solution
An ice maker that forms multiple clear ice sheets on evaporator plates and fuses them in a staging apparatus to create a unitary clear ice sheet, which can then be molded into desired structures, minimizing the distance between the cold plate and the water-ice interface and enhancing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If layers of running water are frozen on a cold plate in a single operation to form a clear ice block of sufficient thickness, then the required thickness for molding ice structures is achieved, but the freezing time becomes excessively prolonged
Solution Approach 1:
The ice block formation process is divided into multiple separate freezing operations, where thin ice sheets are formed individually on cold plates and then stacked to achieve the required thickness. Each sheet is frozen in a short time period, avoiding the prolonged freezing time that would occur if a single thick block were formed in one operation.
Solution Approach 2:
The approach transitions from building thickness in the vertical dimension through continuous freezing to achieving thickness through stacking multiple thin sheets in the vertical dimension. This dimensional strategy allows the required thickness to be achieved by combining multiple thin frozen layers rather than freezing one thick layer, significantly reducing total freezing time.
2Loss of time
If multiple ice sheets are formed and stacked to achieve required thickness, then freezing time is reduced, but visual flaws may appear at the fusion planes between sheets
Solution Approach 1:
A release film is applied to the cold plate surface before freezing each ice sheet. This thin film acts as a barrier that prevents direct bonding between the ice sheet and the cold plate, allowing the sheet to be easily removed and stacked. The film ensures clean separation and prevents unwanted adhesion that could create visual flaws at the fusion planes when sheets are stacked.
Solution Approach 2:
The cold plate is prepared in advance by applying the release film and positioning the mold form before the water is introduced for freezing. This preliminary preparation ensures that when the thin ice sheet forms, the mold form is already in place to guide proper alignment and stacking, preventing misalignment that would create visual flaws at fusion planes.
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 method allows for the rapid formation of a thicker clear ice sheet, reducing the time required to achieve the necessary thickness for molding ice structures, while maintaining clarity and minimizing visual flaws at fusion planes.
Implementation Method 1
The first side of the evaporator plate is adapted to form a first clear ice sheet and the second side of the evaporator plate is adapted to form a second clear ice sheet
Implementation Method 2
layers of running water may be frozen on a cold plate
Implementation Method 3
The first and second clear ice sheets are fused in the staging apparatus to form a unitary clear ice sheet
Data Source
AI summary
An ice maker is provided herein that includes an evaporator plate. A first side of the evaporator plate is adapted to form a first clear ice sheet and a second side of the evaporator plate is adapted to form a second clear ice sheet. A staging area is arranged downstream from the evaporator plate and adapted to receive the first and second clear ice sheets after formation. The first and second clear ice sheets are fused in the staging area to form a unitary ice sheet. A first mold assembly having a first mold form and a second mold assembly having a second mold form are positioned within the staging area on opposite sides of the unitary ice sheet when the unitary ice sheet is received in the staging area. A mold cavity is adapted to shape the unitary clear ice sheet to form one or more clear ice structures.