Ice machine with enhanced directional freezing capability
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Solution Overview
Problem
Existing ice machines face challenges in producing clear ice efficiently, requiring large storage space, high costs, and lack integrated storage solutions, while industrial-scale machines are unsuitable for compact environments and consumer-grade models lack production capacity and require manual intervention.
Innovation Solution
A compact ice machine with a control system that automates the production, freezing, and transfer of directionally-frozen ice segments using a grid mold with embedded heat wires and slanted guides, integrated storage, and a funnel to expedite the transfer process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If industrial-scale clear ice machines are used, then production capacity and cost-effectiveness are improved, but physical footprint and space requirements increase
Solution Approach 1:
The ice machine is divided into distinct functional modules: an upper freezing chamber with grid mold for ice segment production, and a lower storage chamber for accumulated ice. This segmentation allows each module to be optimized independently, enabling compact overall dimensions while maintaining industrial-scale production capacity through automated multi-cycle operation.
Solution Approach 2:
The grid mold is nested within the freezing chamber, and the storage container is positioned directly beneath the freezing chamber, creating a vertical nested arrangement. This nesting approach maximizes space utilization by stacking functional zones vertically rather than horizontally, significantly reducing the machine's footprint while preserving production capacity.
2Productivity
If in-house industrial-scale ice machines are used, then cost-effectiveness is improved, but integrated storage solutions and automation capability are reduced
Solution Approach 1:
The machine merges the freezing chamber and storage container into a single integrated unit, with the storage container directly receiving ice segments from the freezing chamber through the aperture. This combination eliminates the need for external manual transfer operations, providing automated storage capability while maintaining cost-effectiveness through in-house production.
Solution Approach 2:
The grid mold incorporates slanted guides that automatically direct frozen ice segments into the storage container without human intervention. The system serves itself by utilizing gravity and the molded geometry to transfer ice from production to storage, eliminating manual labor while maintaining operational efficiency.
3Manufacturing precision
If directional freezing is used, then ice clarity and solidity are improved, but production time and system complexity increase
Solution Approach 1:
The grid mold features insulated sidewalls with embedded heat wires at specific locations to control the freezing front direction. The insulation is applied selectively to the sidewalls rather than the entire mold, and heat wires are positioned to facilitate directional freezing from bottom to top. This localized application of thermal control features achieves clear ice production while minimizing overall system complexity.
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
Enables efficient production and storage of clear ice segments with reduced system complexity, minimizing waste and optimizing space usage, suitable for high-volume demand without manual intervention.
Implementation Method 1
the condenser and the one or more fans directionally freeze the liquid in the cavities of the grid mold in one direction, for example top to bottom
Implementation Method 2
The control system activates the embedded heat wires to partially melt the directionally-frozen ice segments. By heating the exterior of the ice segments, the embedded heat wires activate the movement of the ice segments.
Data Source
AI summary
Various embodiments of the present disclosure relate to an ice machine capable of producing directionally-frozen ice segments. In one example embodiment an ice machine includes a basin having four sidewalls and a bottom. The bottom of the basin includes an aperture, which is exposed or enclosed by a gate valve located on the aperture. The ice machine includes a grid mold inset to the basin. The grid mold includes exterior and interior sidewalls to form cavities which house a liquid that is directionally frozen by the condenser and overhead fans of the ice machine. The ice machine includes heat wires embedded into the exterior and interior sidewalls of the grid mold. The ice machine includes a funnel beneath the grid mold to guide the ice segments from the grid mold, through the aperture, and into a storage container.