Ice Log and Beam Molding for Predictable Structure Assembly
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Solution Overview
Problem
Existing methods for constructing ice structures, such as ice castles or palaces, face challenges including unpredictable icicle formation, inconsistent icicle thickness and density, high water usage, discomfort and risk of frostbite for workers due to wet snow, and unpredictable water spraying patterns due to warm sprinkler tubing.
Innovation Solution
The method involves forming elongate ice logs by filling sleeves with water, allowing them to freeze, and then using these logs to build structures, which can be cut to specific sizes and shapes for stability and aesthetic purposes, with thermally isolated water tubes to prevent ice damage and using molds for forming ice beams with flat sides for stacking without slush.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If icicles are used to form the initial structure, then the structure can be built, but the icicle formation is unpredictable and inconsistent in thickness and density
Solution Approach 1:
The patent applies preliminary action by pre-forming ice logs in molds with water before constructing the ice structure. This allows the ice components to be prepared in advance with controlled dimensions and properties, eliminating the unpredictability of on-site icicle formation. The molds ensure consistent thickness and density before the logs are transported and assembled into the final structure.
Solution Approach 2:
The patent changes the parameters of ice formation by controlling temperature, pressure, and mold geometry during the ice log production process. By adjusting these parameters in the mold, the invention achieves consistent thickness and density that cannot be obtained through natural icicle formation. This parameter control resolves the manufacturing precision issue while maintaining reliability.
2Ease of manufacture
If a substantial amount of water is used to form icicles, then the initial structure can be created, but water usage becomes excessive
Solution Approach 1:
The patent uses preliminary action by pre-forming ice logs in molds where water is efficiently utilized. The molds capture and freeze exactly the amount of water needed for each log, eliminating waste from runoff and evaporation during on-site construction. This approach maintains ease of manufacture while dramatically reducing water consumption compared to traditional icicle formation methods.
Solution Approach 2:
The patent applies discarding and recovering by using leftover water from the ice log formation process to create additional ice logs or to moisten the construction area. This recovery approach ensures that minimal water is wasted, addressing the loss of substance issue while maintaining the ease of structure formation.
3Ease of operation
If slush is used to attach icicles to the frame, then the structure can be assembled, but workers experience discomfort and risk of frostbite
Solution Approach 1:
The patent applies preliminary action by pre-assembling ice logs in controlled environments where slush is minimized. The logs are prepared and transported in a semi-frozen state, allowing workers to assemble the structure with less exposure to extreme cold and wet conditions. This maintains ease of operation while reducing the harmful effects on workers.
Solution Approach 2:
The patent uses disposable insulation materials and protective coverings during the assembly process that can be quickly applied and removed. These temporary protective measures shield workers from the harmful effects of slush and cold, allowing easy assembly without prolonged exposure to frostbite risks.
4Productivity
If PVC sprinkler tubing is used to spray water, then the structure can be grown, but the warm tubing cuts through the ice and creates unpredictable water patterns
Solution Approach 1:
The patent introduces an intermediary thermal insulation layer between the PVC sprinkler tubing and the ice structure. This insulation mediator prevents heat transfer from the warm tubing to the ice, eliminating the cutting effect and ensuring predictable water spray patterns. The productivity is maintained while the reliability of the spraying pattern is improved through this intermediary protection.
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 provides greater predictability and control over ice structure construction, reduces water waste, enhances worker safety, and allows for faster and more stable building of complex designs with improved aesthetic appeal by using translucent ice logs and beams.
Implementation Method 1
filling elongate sleeves with water and allowing them to freeze
Implementation Method 2
thermally isolated water tubes to prevent ice damage
Data Source
AI summary
A method for building an ice structure includes making a plurality of ice logs or ice beams and attaching the ice logs together to form a support structure. The support structure may be two or more stories high and may be constructed by freezing the ice logs or ice beams together.