Layered ice maker appliance
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Solution Overview
Problem
Conventional ice maker appliances produce monolithic, homogenous ice pieces that lack visual aesthetic appeal and are perceived as bland.
Innovation Solution
An ice maker appliance with a mold body comprising two or more mold cavities and a controller that controls the flow and retention of liquid volumes into these cavities to form distinct layers of ice pieces, including layers of plain and infused ice.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional ice makers produce monolithic, homogenous ice pieces, then the manufacturing process is simple, but the visual aesthetic appeal and taste quality deteriorate
Solution Approach 1:
The ice making process is segmented into multiple sequential stages, with each stage filling the mold cavity with a different liquid composition (e.g., water, infused liquids, flavorings). This creates distinct layers within the ice piece, transforming the single-stage homogenous freezing process into a multi-stage differentiated process that enhances visual appeal while maintaining manufacturing simplicity
Solution Approach 2:
Different regions of the ice piece are given different qualities by introducing various liquid compositions at different stages. Each layer has unique characteristics (flavor, color, clarity) based on the specific liquid used, creating local quality variations throughout the ice structure while using the same basic mold and freezing mechanism
2Illumination intensity
If multiple volumes of liquid are flowed into mold cavities at different times to form distinct layers, then visual aesthetic appeal and taste quality improve, but the device complexity and control requirements worsen
Solution Approach 1:
The mold body is designed with multi-functionality by incorporating multiple fill tubes that can each deliver different liquid compositions. The same mold structure serves multiple purposes: it defines the ice shape, manages multiple liquid inputs, and controls the layering process, reducing the need for additional complex components
Solution Approach 2:
The controller is pre-programmed with sequential control logic that automatically manages the timing and sequence of liquid deliveries. By embedding the control sequence in advance, the system eliminates the need for real-time complex decision-making during operation, simplifying the control architecture while achieving precise multi-layer formation
3Manufacturing precision
If liquid volumes are retained in mold cavities for predetermined times to form layers, then distinct layered ice pieces are produced, but the production time and efficiency worsen
Solution Approach 1:
The freezing process maintains continuity by eliminating idle time between liquid deliveries. Each subsequent liquid volume is introduced immediately after the previous layer begins forming, and the mold remains continuously occupied with freezing material. This continuous action maximizes space utilization and reduces total production time while maintaining precise layer formation
Solution Approach 2:
The liquid delivery process follows a periodic pattern with predetermined intervals between each fill operation. By optimizing these periodic intervals to match the freezing rate, the system achieves precise layer thickness control without excessive waiting time, balancing manufacturing precision with production efficiency
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
Produces visually distinct and enhanced ice pieces with varying layers, such as clear and cloudy, or infused with additives, enhancing the aesthetic and taste appeal of the ice.
Implementation Method 1
a working fluid is used to directly cool the mold body, e.g., by conductive heat transfer
Implementation Method 2
When the mold body is cooled, directly and/or indirectly, ice may be formed from the liquid water therein
Implementation Method 3
retaining the first volume of liquid in the at least one of the mold cavities for a first predetermined time after flowing the first volume of liquid into the at least one of the mold cavities. As a result, a first layer of an ice piece forms from the first volume of liquid in the mold cavity
Data Source
AI summary
An ice maker appliance includes a fill tube and a mold body. The fill tube is in fluid communication with a water supply. The mold body includes two or more mold cavities. The mold body is positioned downstream of the fill tube. The ice maker appliance may be operable for, or a method of operating the ice maker appliance may include, flowing a first volume of liquid into at least one of the mold cavities. The first volume of liquid may be retained in the mold body, such that a first layer of an ice piece forms. A second volume of liquid may be flowed into the at least one mold cavity after the first layer of ice forms and may be retained to form a second layer of the ice piece. The second layer of the ice piece is distinct from the first layer of the ice piece.