Ice Machine With Reduced Footprint
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Solution Overview
Problem
Existing ice machines have a large footprint, require extensive storage for manufactured ice, and are susceptible to theft and staleness, with slow bagging rates and inflexible throughput, leading to inefficiencies in space utilization and ice quality.
Innovation Solution
An ice machine with a compact design featuring a frame, cabinet, and integrated ice maker, hopper system, auger, bagging system, and refrigerated storage, including sensors and a sealing mechanism to rapidly produce and bag ice, ensuring efficient space utilization and ice quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large storage compartment is used to hold substantial quantities of ice, then the ice machine can meet demand with slow bagging rates, but the footprint becomes very large (larger than six feet in length and four feet in depth)
Solution Approach 1:
The ice storage system is segmented into multiple smaller hoppers (first ice hopper, second hopper, third hopper) arranged in series, each with a smaller footprint than a single large storage compartment. This segmentation allows the system to maintain adequate ice supply while reducing the overall space required, as each hopper only needs to hold enough ice for its specific bagging operation rather than storing large quantities in one location.
Solution Approach 2:
The patent transitions from a horizontal layout with a large single storage compartment to a vertical arrangement with multiple stacked hoppers. The hoppers are positioned one above another, utilizing vertical space rather than horizontal space. This dimensional change allows the system to maintain the required ice storage capacity while significantly reducing the footprint area occupied by the ice machine.
2Productivity
If multiple hoppers with substantial ice reserves are used, then the system can operate with slow bagging rates, but additional components are required to break up ice, prevent thawing and refreezing, and maintain ice quality
Solution Approach 1:
The ice maintenance function is segmented and assigned to individual hoppers rather than requiring a single complex maintenance system for the entire storage compartment. Each hopper can be equipped with simple, dedicated maintenance components (such as individual heating elements or ice breakers) tailored to its specific needs, reducing overall system complexity compared to maintaining one large storage compartment.
Solution Approach 2:
Each hopper is designed to maintain its own ice quality independently through self-contained maintenance mechanisms. The hoppers can automatically prevent thawing and refreezing, break up ice, and maintain proper ice conditions without requiring external intervention or complex centralized control systems. This self-service approach reduces the number of components needed compared to a system requiring manual or centralized maintenance of large ice reserves.
3Productivity
If large quantities of ice are stored for extended periods, then demand can be met, but the ice becomes stale and the storage section is susceptible to theft
Solution Approach 1:
The ice storage is divided into multiple smaller hoppers that process and bag ice in sequence, reducing the time any single portion of ice remains in storage. This segmentation ensures that ice moves continuously through the system from production to bagging, minimizing the duration that ice sits in storage and thereby maintaining freshness and quality while still meeting demand through continuous production.
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 compact ice machine efficiently produces and bags ice quickly, minimizing storage needs and reducing theft risks while maintaining ice quality, with flexible throughput and customizable ice production to meet demand.
Implementation Method 1
an auger extending along a portion of the first ice hopper to move ice to an opening
Implementation Method 2
a sealing system and a chute extending from and pivotable about the second hopper
Data Source
AI summary
An ice machine is provided that has a minimal footprint, while still being able to quickly and efficiently fill bags of ice. The machine has a cabinet, a frame within the cabinet, and an ice maker mounted to the cabinet and/or the frame. Once the ice maker has made ice, the ice is deposited into a hopper. The ice machine may have multiple hoppers through which the ice is guided to a bagging system. Once the ice has been inserted into a bag by the bagging system, the filled bag is sealed. Once the bag has been sealed, it can be delivered to a customer, otherwise it can be stored in a cooler section. The ice machine has a number of high power motors that enable fast movement of the ice to generate the bags of ice in minimal time.