Ice Ball Molding With Uniform Heating for Crack-Free Hail Testing
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Solution Overview
Problem
Existing methods for producing ice balls for testing building materials' resistance to hailstorms fail to ensure crack-free and pore-free ice balls with sufficient manufacturing tolerance for accurate and consistent results.
Innovation Solution
The method involves uniformly heating the lower and upper molds during the melting process, immediate removal of the melted ice ball from the mold to prevent shape and dimensional errors, and ensuring uniform heat transfer by cooling the ice cubes and using a device with hemispherical mold spaces and radial drainage channels to maintain shape accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the mold is heated to a specified starting temperature before melting, then the melting process can be initiated, but temperature differences occur during melting leading to cracks and shape inaccuracies
Solution Approach 1:
The patent applies dynamics by transitioning from a static preheated mold to a dynamically controlled heating system. The mold heating temperature is continuously adjusted during the melting process based on real-time monitoring of ice cube melting progress, ensuring uniform temperature distribution and preventing thermal shocks that cause cracks and shape deviations.
Solution Approach 2:
The patent implements feedback control by monitoring the melting progress of ice cubes in real-time and using this information to adjust the mold heating temperature. This closed-loop control system ensures that the mold temperature remains optimal throughout the melting process, preventing temperature differences that would otherwise lead to cracks and shape inaccuracies.
2Duration of action of stationary object
If the melting process continues in the closed mold, then the ice ball forms completely, but subsequent melting causes shape and dimensional errors
Solution Approach 1:
The patent applies preliminary action by determining the optimal melting time in advance based on ice cube size and mold temperature, then removing the ice ball at precisely this moment. This prevents over-melting and ensures the ice ball achieves the desired shape and dimensional accuracy without excessive melting that would cause errors.
Solution Approach 2:
The patent implements self-service through an automatic detection system that monitors when the ice cube has completely melted into the hemispherical mold cavity. The system automatically triggers the ejection mechanism at the precise moment of complete melting, eliminating the need for manual timing and ensuring consistent dimensional accuracy.
3Manufacturing precision
If the ice ball is removed from the mold immediately after melting, then shape accuracy is maintained, but the meltwater film must be removed to prevent freezing errors
Solution Approach 1:
The patent uses a moisture-absorbing cloth as an intermediary tool to remove the meltwater film from the ice ball surface. This simple intermediary element effectively prevents the water film from refreezing and causing shape errors, while adding minimal complexity to the manufacturing process.
Solution Approach 2:
The patent replaces complex mechanical drying systems with a simple absorbent material approach. Instead of using heated air streams, rotating drums, or other mechanical drying mechanisms, the meltwater film is removed using moisture-absorbing cloths or paper towels, simplifying the handling process while maintaining shape accuracy.
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 approach produces ice balls that are consistently crack-free and pore-free, maintaining shape and size accuracy, essential for reliable testing of building materials' resistance to hailstorms.
Implementation Method 1
The lower and upper molds are each provided with flow channels (6), which can be acted upon by a flow (7) with a heat transfer medium, preferably water
Implementation Method 2
the ice cube placed on the lower mold (1) is melted in the area of the parting surfaces
Implementation Method 3
The molding tool also has a signal generator that responds to the closing of the upper and lower molds
Implementation Method 4
the lower mold has radial drainage channels for melt water in the parting surface to the upper mold
Data Source
Figure 1~2
Figure 3
AI summary
A method for producing ice balls is described, whereby water is first frozen from bottom to top to form a block of ice and the block of ice is then sawed into cubes before the cubes are placed in a heated mold with hemispherical mold cavities (4) with a lower mold and an upper mold ( 1, 2) are melted into a sphere during the closing of the lower and upper molds (1, 2). In order to obtain crack-free ice balls, it is proposed that the lower and upper molds (1, 2) be heated uniformly during closing and that the melted ice ball be removed from the mold immediately after the lower and upper molds (1, 2) have been closed and freed from the remaining meltwater film