Ice Sheet Cutting for Faster Small-Form Ice Production
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Solution Overview
Problem
Current ice manufacturing systems are inefficient, wasteful, and hazardous due to the use of single-use liners, slow freezing processes, and labor-intensive manual handling of large ice blocks, leading to energy waste, safety concerns, and uneven ice quality.
Innovation Solution
A system and method for converting large form ice units into smaller form ice units using a formation module and a converting station with cutting mechanisms, including a first and second cutting station, capable of cutting ice sheets into elongated segments and further into small form ice units, utilizing reusable liners and directional freezing to enhance efficiency and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If single-use liners are used in ice block makers, then ice blocks can be easily removed and food safety is improved, but production time increases and waste is generated
Solution Approach 1:
The patent employs single-use disposable liners made of food-safe materials that are discarded after one use. These liners prevent ice blocks from sticking to the mold, ensure food safety by eliminating contamination risks from reusable liners, and facilitate easy removal of ice blocks without requiring cleaning or maintenance of the mold itself.
2Manufacturing precision
If water is slowly circulated to remove air bubbles, then clear ice blocks are produced, but the freezing process takes several days
Solution Approach 1:
The patent incorporates air bubble removal mechanisms that operate during the initial stages of freezing before the ice block fully forms. By preliminarily addressing air bubble entrapment through controlled water circulation and degassing systems, the patent achieves clear ice without requiring extended freezing times, thus resolving the contradiction between ice clarity and production speed.
3Adaptability or versatility
If large ice blocks are manually handled and cut, then small form ice units can be produced, but labor intensity increases and safety concerns arise
Solution Approach 1:
The patent replaces manual handling and cutting operations with automated mechanical systems. Conveyor belts transport ice blocks through cutting stations where computer-controlled saws automatically divide large ice blocks into various small form units (cubes, spheres, shards). This automation eliminates manual labor risks, ensures consistent cutting precision, and allows flexible production of different ice forms without increasing labor intensity.
4Reliability
If disposable liners are used for each ice block, then food safety is ensured, but material waste increases
Solution Approach 1:
The patent uses inexpensive disposable liners made from food-safe materials such as parchment paper, silicone, or plastic that can be easily discarded after single use. These liners prevent ice blocks from adhering to the mold, ensure no contamination of ice blocks, and their low cost makes the environmental impact acceptable compared to the food safety benefits gained.
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 system significantly reduces production time, energy consumption, and handling risks while producing high-quality small form ice units, such as cubes and sculptures, with improved throughput and reduced waste.
Implementation Method 1
The freezing module may include a plate freezer and/or may be incorporated in a system for manufacturing ice. Any method for forming large form ice blocks or ice sheets for conversion into a plurality of small form ice products may be used.
Data Source
AI summary
A system and method for making small form ice units is provided. More specifically, a novel and advantageous system and method for converting a large form ice unit into smaller form ice units is provided. Even more specifically, a novel and advantageous system and method for forming an ice sheet and for dividing an ice sheet into a plurality of elongated segments, such as ice rods, and the elongated segments into a plurality of small form ice units, such as ice cubes is provided. The system may include a formation module for forming a large form ice structure and a converting station for converting the large form ice structure to small form ice units.