Ice machine with a dual-circuit evaporator for hydrocarbon refrigerant
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Commercial ice making machines face challenges in increasing ice production capacity while adhering to hydrocarbon refrigerant charge limitations and reducing manufacturing costs, with existing solutions either being unproven or leading to increased warranty costs due to component failures.
Innovation Solution
A single evaporator assembly is attached to dual, independent hydrocarbon refrigeration circuits with serpentine-shaped refrigerant tubings interleaved for even temperature distribution, allowing for higher ice production within safe refrigerant limits and conserving material costs by using a single evaporator and water circulation system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single evaporator is used with dual refrigeration circuits, then ice production capacity increases within refrigerant charge limits, but system complexity increases due to dual independent circuits
Solution Approach 1:
The refrigeration system is divided into two independent circuits, each with its own compressor, condenser, and expansion device, allowing separate control and operation of each circuit while sharing a common evaporator and refrigerant charge
Solution Approach 2:
The single evaporator serves both refrigeration circuits simultaneously, allowing the system to achieve higher ice production capacity within the allowable refrigerant charge limit by utilizing the evaporator's full surface area with both circuits
2Productivity
If hydrocarbon refrigerant charge is increased to boost ice capacity, then ice production increases, but safety risks increase due to flammability concerns
Solution Approach 1:
The refrigerant charge is divided between two independent circuits, with each circuit containing approximately half the total charge. This segmentation allows the system to operate at higher total capacities while maintaining lower charge levels in each individual circuit, thereby reducing safety risks associated with hydrocarbon flammability
3Productivity
If traditional dual evaporator systems are used to increase capacity, then ice production capacity increases, but manufacturing costs increase due to additional components
Solution Approach 1:
The system merges two refrigeration circuits into a single evaporator assembly, eliminating the need for separate evaporators and reducing the number of components required. This consolidation maintains high ice production capacity while reducing manufacturing costs through fewer parts and simplified assembly
4Stability of the object's composition
If serpentine-shaped interleaved tubings are used in evaporator, then temperature distribution evenness improves, but manufacturing complexity of evaporator increases
Solution Approach 1:
The refrigerant tubings are formed into serpentine shapes with curved paths instead of straight lines, allowing the tubes to be interleaved in a pattern that distributes refrigerant flow evenly across the evaporator surface. This curved configuration improves temperature distribution while remaining manufacturable using standard tubing forming techniques
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 solution enables higher ice capacities while ensuring safe operation within hydrocarbon refrigerant limits, reducing manufacturing costs, and providing a reliable method for ice production, thus addressing the limitations of existing solutions.
Implementation Method 1
a single evaporator assembly attached to dual, independent hydrocarbon refrigeration circuits with serpentine-shaped refrigerant tubings interleaved for even temperature distribution
Implementation Method 2
using refrigerant capable of transitioning between liquid and gaseous states
Implementation Method 3
an ice making assembly for forming ice using refrigerant capable of transitioning between liquid and gaseous states
Data Source
AI summary
An ice making machine having a refrigeration system designed for hydrocarbon (HC) refrigerants, and particularly propane (R-290), that includes dual independent refrigeration systems and a unique evaporator assembly comprising of a single freeze plate attached to two cooling circuits. The serpentines are designed in an advantageous pattern that promotes efficiency by ensuring the even bridging of ice during freezing and minimizing unwanted melting during harvest by providing an even distribution of the heat load. The charge limitations imposed with flammable refrigerants would otherwise prevent large capacity ice maker from being properly charged with a single circuit. The ice making machine includes a single water circuit and control system to ensure the proper and efficient production of ice. Material cost is conserved as compared to a traditional dual system icemaker.