Patent Grant
11408659
All publications and patent applications mentioned in this specification are herein incorporated by reference in their entirety, as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference in its entirety.
This disclosure relates generally to the field of ice manufacturing, and more specifically to the field of clear ice manufacturing. Described herein are devices and methods for producing clear ice.
From the end of the prohibition era to modern day, craft cocktails are a mainstay in most restaurants and bars. To enhance the overall experience, some restaurants and bars add garnishes and/or specialty ice to the cocktails. Currently, these restaurants and bars buy large blocks of ice that are then cut down in-house to the appropriate size for each drink. Some companies in the space claim to produce clear ice using directional freezing, but the clarity of the ice and scalability of the technology are questionable with many techniques often requiring the use of dangerous saws to cut down larger blocks of ice. Further, issues with standard ice machines include cracking, trapped air bubbles, and water impurities resulting in ice that lacks the desired appeal and appearance.
Ice can crack under a variety of circumstances experienced during or after a freezing process. Sometimes, during the freezing process, when the exterior of the ice freezes first and then further cools during subsequent freezing, interior tension in the ice is created. This interior tension causes cracking of the ice when it exceeds a certain threshold (e.g., about 1 MPa). Unclear ice may result from super cooling. Water crystallizes around nucleation sites. The ice then grows from this point forming a near perfect lattice structure, given the proper environment. For example, some ice machines slightly super cool the water before freezing. This causes smaller, faster crystallization, which can lead to uneven pressure and greater cloudiness. Lastly, impurities in the water used for freezing can create unclear ice. While impurities play a role in the imperfections in ice, they often aren't the main culprit. Filtered water has on average 30 ppm impurities
In other cases, some ice machines create cloudy ice because the water contains dissolved air, whereas clear ice contains almost none. During the freezing process, as water turns to ice, and the remaining water reaches saturation level for dissolved gases, the dissolved gas comes out of solution. The gas bubbles stick to the ice-water interface due to surface adhesion. If these gas bubbles do not get released, they become frozen into the ice, resulting in optical imperfections which affect the straight passage of light (i.e., “cloudiness”).
Furthermore, many extant clear ice machines produce large and unwieldly blocks that are far too large for convenient use in a cocktail as a comestible. In addition to the long freezing times usually required to produce them, often around 24 to 72 hours, these large blocks must be cut down to a size useful as a comestible. Much time and effort then, is expended to produce even a simple and solid shape of clear ice for use in a cocktail.
Taken together, improper ice freezing techniques and equipment result in less-than-ideal ice for the booming craft cocktail industry. Thus, there is a need for new and useful devices and methods for creating clear ice.
There is a need for new and useful device and method for producing clear ice specifically for use in beverages. In some embodiments, the disclosure herein provides for a device for making clear ice comprising: at least one housing comprising at least two flume surface walls that define at least two elongate troughs arranged parallel to each other; at least one fluid intake disposed to provide a flow of fluid into the at least two elongate troughs; at least one drain disposed to drain fluid from the at least two elongate troughs; wherein the at least a portion of each of the at least two flume surface walls is in thermal communication with a cooling source; wherein the at least one fluid intake and the at least one drain are configured to provide a substantially constant flow of fluid to the at least two elongate troughs during a freezing operation of the device; wherein the fluid intake comprises a fluid intake manifold that defines a single intake manifold cavity that is fluidly connected to the at least two elongate troughs through a fluid entry portal corresponding to each elongate trough; and wherein the drain comprises a drain manifold that defines a single drain manifold cavity that is fluidly connected to the at least two elongate throughs through a fluid exit portal corresponding to each elongate trough. In some embodiments, the cooling source is selected from the group consisting of: an internal cooling cavity defined by the housing, an evaporator, a cold plate, and a condenser.
In some embodiments, the disclosure herein includes for a device for making clear ice comprising: at least one housing comprising at least one flume surface wall that defines at least one elongate trough; at least one fluid intake disposed to provide a flow of fluid into the at least one elongate trough; at least one drain disposed to drain fluid from the at least one elongate trough; wherein the at least a portion of the at least one flume surface wall is in thermal communication with a cooling source; and wherein the at least one fluid intake and the at least one drain are configured to provide a substantially constant flow of fluid to the at least one elongate trough during a freezing operation of the device. In some embodiments, the cooling source is selected from the group consisting of: an internal cooling cavity defined by the housing, an evaporator, a cold plate, and a condenser.
In some embodiments, three flume surface walls of the housing define one elongate trough such that a cross-section of the elongate trough has a tapered U-shape defined by at least one of the two side flume surface walls having an interior angle greater than or equal to about 0 degrees and less than or equal to about 15 degrees from upright and a semicircular base flume surface wall. In other embodiments, three flume surface walls of the housing define one elongate trough such that a cross-section of the elongate trough has a tapered bracket shape defined by at least one of the two side flume surface walls having an interior angle greater than or equal to about 0 degrees and less than or equal to about 15 degrees from upright to a flat base flume surface wall. In some embodiments, the elongate trough has a total depth divided into an ice-forming zone and a fluid overflow zone, and wherein a surface area of the flume surface wall at least coextensive with the fluid overflow zone comprises a thermally insulating material.
In some embodiments, the housing comprises at least two flume surface walls that define two or more elongate troughs, and wherein the fluid intake comprises a fluid intake manifold that defines a single intake manifold cavity that is fluidly connected to the two or more elongate troughs through a fluid entry portal corresponding to each elongate trough. In further embodiments, the fluid intake manifold further comprises an intake flow divider insert having a porosity of about 10% open area to about 50% open area within the intake manifold cavity, the intake manifold cavity is shaped as a rectangular prism, and the intake flow divider insert is coupled to opposite corners of the intake manifold cavity, thereby dividing the intake manifold cavity into a first and second triangular prism, wherein at least one fluid inlet pipe is in fluid communication to the first triangular prism, and wherein the corresponding fluid entry portals are in fluid communication to the second triangular prism. In additional embodiments, at least one of the fluid entry portals comprises a porous flow straightener insert.
In some embodiments, the housing comprises at least two flume surface walls that define two or more elongate troughs, and wherein the drain comprises a drain manifold that defines a single drain manifold cavity that is fluidly connected to the two or more elongate throughs through a fluid exit portal corresponding to each elongate trough. In further embodiments, the drain manifold further comprises a drain flow divider insert having a porosity of about 10% open area to about 50% open area within the drain manifold cavity, the drain manifold cavity is shaped as a rectangular prism, and the drain flow divider insert forms an arcuate shape and is coupled to adjacent corners of the drain manifold cavity, thereby dividing the drain manifold cavity into a first and second portion wherein at least one drainage pipe is in fluid communication to the first portion, and wherein the corresponding fluid exit portals are in fluid communication to the second portion. In additional embodiments, at least one of the fluid exit portals comprises a porous flow straightener insert.
In some embodiments, the substantially constant flow of fluid is provided at a velocity of at least about 0.09 m/s (about 0.3 ft/s) through the at least one elongate trough. In further embodiments, the device further comprises at least one lid configured to enclose at least one elongate trough when removably coupled to the housing. In additional embodiments, the device further comprises one or more retractable inclusion holders configured to be disposed within a cavity defined by the at least one elongate trough.
In some embodiments, the disclosure herein provides for a method for manufacturing clear ice comprising: providing a device for making clear ice comprising: a housing comprising at least one flume surface wall that defines at least one elongate trough; at least one fluid intake disposed to provide a flow of fluid into the at least one elongate trough; at least one drain disposed to drain fluid from at least one elongate trough; wherein the at least a portion of the at least one flume surface wall is in thermal communication with a cooling source; and wherein the at least one fluid intake and the at least one drain are configured to provide a substantially constant flow of fluid to the at least one elongate trough during a freezing operation of the device; providing a substantially constant flow of fluid down the at least one elongate trough via the fluid intake and the drain; and cooling the at least one flume surface wall to a temperature of less than or equal to about 0 degrees Celsius at the at least one flume surface wall. In some embodiments of the method, the cooling source is selected from the group consisting of: an internal cooling cavity defined by the housing, an evaporator, a cold plate, and a condenser. In further embodiments, the clear ice machine further comprises: at least one or more retractable inclusion holders configured to be disposed within at least one elongate trough; and the method further comprises: securing an item with at least one inclusion holder such that the item is positioned within a cavity defined by the at least one elongate trough; and retracting the one or more retractable inclusion holders after a sufficient accumulation of ice within the elongate trough such that the item remains at least partially embedded in the accumulation of ice upon retraction of the one or more inclusion holders. In additional embodiments of the method, the substantially constant flow of fluid down the at least one elongate trough has a velocity of at least about 0.09 m/s (about 0.3 ft/s) through the at least one elongate trough.
In many embodiments, the disclosure herein includes for a device for making clear ice comprising: at least one housing comprising at least one flume surface wall that defines at least one elongate trough; at least one fluid intake disposed to provide a flow of fluid into the at least one elongate trough; at least one drain disposed to drain fluid from at least one elongate trough; wherein the at least a portion of the at least one flume surface wall is in thermal communication with a cooling source; and wherein the at least one fluid intake and the at least one drain are configured to provide a substantially constant flow of fluid to the at least one elongate trough during a freezing operation of the device. In some embodiments, the cooling source is at least one internal cooling cavity defined by the housing, and wherein the device further comprises at least one coolant intake connected to the at least one internal cooling cavity and at least one coolant outtake connected to the at least one internal cooling cavity. In other embodiments, the cooling source is selected from the group consisting of: an evaporator, cold plate, and a condenser.
In certain embodiments, three flume surface walls of the housing define one elongate trough such that a cross-section of the elongate trough has a U-shape defined by two parallel side flume surface walls and a semicircular base flume surface wall. In other embodiments, three flume surface walls of the housing define one elongate trough such that a cross-section of the elongate trough has a tapered U-shape defined by at least one of the two side flume surface walls having an interior angle greater than about 0 degrees and less than or equal to about 15 degrees from upright and a semicircular base flume surface wall.
In further embodiments, three flume surface walls of the housing define one elongate trough such that a cross-section of the elongate trough has a U-shape defined by two parallel side flume surface walls and a semi-elliptical base flume surface wall. In other embodiments, three flume surface walls of the housing define one elongate trough such that a cross-section of the elongate trough has a tapered U-shape defined by at least one of the two side flume surface walls having an interior angle greater than about 0 degrees and less than or equal to about 15 degrees from upright and a semi-elliptical base flume surface wall.
In additional embodiments, three flume surface walls of the housing define one elongate trough such that a cross-section of the elongate trough has a bracket shape defined by two parallel side flume surface walls orthogonal to a flat base flume surface wall. In other embodiments, three flume surface walls of the housing define one elongate trough such that a cross-section of the elongate trough has a tapered bracket shape defined by at least one of the two side flume surface walls having an interior angle greater than about 0 degrees and less than or equal to about 15 degrees from upright to a flat base flume surface wall.
In some embodiments, the elongate trough has a length of about 45.72 cm to about 3.66 m (about 18 inches to about 12 feet). In other embodiments, the elongate trough has a length of about 2.44 m to about 2.13 m (about 3 feet to about 7 feet). In further embodiments, the elongate trough has a length of about 2.03 m (about 80 inches). In some embodiments, the elongate trough has a depth of about 3.81 cm to about 12.70 cm (about 1.5 to about 5 inches). In other embodiments, the elongate trough has a depth of about 8.89 cm (about 3.5 inches). In some embodiments, the elongate trough has a total depth divided into an ice-forming zone and a fluid overflow zone. In other embodiments, the elongate trough has a total depth of about 12.70 cm (about 5 inches) divided into an ice-forming zone of about 8.89 cm (about 3.5 inches) and a fluid overflow zone of about 3.81 cm (about 1.5 inches.) In further embodiments, a surface area of the flume surface wall at least coextensive with the fluid overflow zone comprises a thermally insulating material. In additional embodiments, the thermally insulating material comprises high density polyethylene. In some embodiments, the elongate trough has a width of about 2.54 cm to about 12.70 cm (about 1 to about 5 inches.) In other embodiments, the elongate trough has a width of about 7.62 cm (about 3 inches.) In some embodiments, the housing defines two or more elongate troughs positioned parallel to one another. In further embodiments, the two or more elongate troughs are positioned anti-parallel to one another.
In some embodiments, the fluid intake comprises a fluid intake manifold that defines a single intake manifold cavity that is fluidly connected to the two or more elongate troughs through a fluid entry portal corresponding to each elongate trough. In further embodiments, the fluid intake manifold further comprises an intake flow divider insert having a porosity of about 10% open area to about 50% open area within the intake manifold cavity. In additional embodiments, the intake manifold cavity is shaped as a rectangular prism and wherein the intake flow divider insert is coupled to opposite corners of the intake manifold cavity, thereby dividing the intake manifold cavity into a first and second triangular prism, wherein at least one fluid inlet pipe is in fluid communication to the first triangular prism, and wherein the corresponding fluid entry portals are in fluid communication to the second triangular prism. In some embodiments, at least one of the fluid entry portals comprises a porous flow straightener insert.
In some embodiments, the drain comprises a drain manifold that defines a single drain manifold cavity that is fluidly connected to the two or more elongate throughs through a fluid exit portal corresponding to each elongate trough. In other embodiments, the drain manifold further comprises a drain flow divider insert having a porosity of about 10% open area to about 50% open area within the drain manifold. In additional embodiments, the drain manifold cavity is shaped as a rectangular prism, and wherein the drain flow divider insert forms an arcuate shape and is coupled to adjacent corners of the drain manifold cavity, thereby dividing the drain manifold cavity into a first and second portion wherein at least one drainage pipe is in fluid communication to the first portion, and wherein the corresponding fluid exit portals are in fluid communication to the second portion. In some embodiments, at least one of the fluid exit portals comprises a porous flow straightener insert.
In some embodiments, the substantially constant flow of fluid is provided at a velocity of at least about 0.09 m/s (about 0.3 ft/s) through the at least one elongate trough. In other embodiments, the substantially constant flow of fluid is provided at a velocity of at least about 0.21 m/s (about 0.7 ft/s) through the at least one elongate trough.
In some embodiments, the device further comprises at least one lid configured to enclose at least one elongate trough when removably coupled to the housing. In other embodiments, the device further comprises one or more inclusion holders configured to be disposed within a cavity defined by the at least one elongate trough. In some embodiments, the one or more inclusion holders are retractable. In additional embodiments, the one or more inclusion holders are coupled to at least one lid configured to enclose at least one elongate trough when removably coupled to the housing.
In many embodiments, the disclosure herein includes for a method for manufacturing clear ice comprising: providing a device for making clear ice comprising: a housing comprising at least one flume surface wall that defines at least one elongate trough; at least one fluid intake disposed to provide a flow of fluid into the at least one elongate trough; at least one drain disposed to drain fluid from at least one elongate trough; wherein the at least a portion of the at least one flume surface wall is in thermal communication with a cooling source; and wherein the at least one fluid intake and the at least one drain are configured to provide a substantially constant flow of fluid to the at least one elongate trough during a freezing operation of the device; providing a substantially constant flow of fluid down the at least one elongate trough via the fluid intake and the drain; and cooling the at least one flume surface wall to a temperature of less than or equal to about 0 degrees Celcius at the at least one flume surface wall. In some embodiments, the cooling source of the device is at least one internal cooling cavity defined by the housing, and wherein the device further comprises at least one coolant intake valve connected to the at least one internal cooling cavity and at least one coolant outtake valve connected to the at least one internal cooling cavity. In other embodiments, the cooling source is selected from the group consisting of: an evaporator, cold plate, and a condenser.
In some embodiments, the clear ice machine of the method further comprises: at least one or more retractable inclusion holders configured to be disposed within at least one elongate trough; and the method further comprises: securing an item with at least one inclusion holder such that the item is positioned within a cavity defined by the at least one elongate trough. In further embodiments, the method further comprises retracting the one or more retractable inclusion holders after a sufficient accumulation of ice within the elongate trough such that the item remains at least partially embedded in the accumulation of ice upon retraction of the one or more inclusion holders.
In some embodiments of the method, the substantially constant flow of fluid down the at least one elongate trough has a velocity of at least about 0.09 m/s (about 0.3 ft/s) through the at least one elongate trough. In other embodiments, the substantially constant flow of fluid has a velocity of at least about 0.21 m/s (about 0.7 ft/s) through the at least one elongate trough.
In many embodiments, the disclosure herein includes for a device for introducing inclusions into clear ice comprising: a rigid substrate; at least one inclusion holder connected to the substrate adapted to secure an item in a predetermined position, wherein the inclusions holder comprises retraction mechanism and at least one of a skewer, hook, or clamp; and wherein the retraction mechanism is configured to disengage the item from an inclusion holder and retract the inclusion holder.
The foregoing is a summary, and thus, necessarily limited in detail. The above-mentioned aspects, as well as other aspects, features, and advantages of the present technology are described below in connection with various embodiments, with reference made to the accompanying drawings.
The illustrated embodiments are merely examples and are not intended to limit the disclosure. The schematics are drawn to illustrate features and concepts and are not necessarily drawn to scale.
The foregoing is a summary, and thus, necessarily limited in detail. The above-mentioned aspects, as well as other aspects, features, and advantages of the present technology will now be described in connection with various embodiments. The inclusion of the following embodiments is not intended to limit the disclosure to these embodiments, but rather to enable any person skilled in the art to make and use the contemplated invention(s). Other embodiments may be utilized, and modifications may be made without departing from the spirit or scope of the subject matter presented herein. Aspects of the disclosure, as described and illustrated herein, can be arranged, combined, modified, and designed in a variety of different formulations, all of which are explicitly contemplated and form part of this disclosure.
It is an object of the present disclosure to describe devices, systems, and methods for creating clear ice. For example, the devices, systems and methods described herein may be configured to produce clear ice in a variety of shapes that are ready for use in beverages.
Disclosed herein are devices and methods for making clear ice. In particular, the disclosure herein provides for devices and methods allowing for the expedited production of clear ice having an improved quality over preexisting apparatuses and methods. In many embodiments, the devices and methods disclosed herein are adapted for the freezing of water into clear ice; however, one of skill in the art will appreciate how these devices and methods can be adapted to allow for the freezing of other liquids (e.g., ethanol, etc.) in situations where the removal of air bubbles and dissolved impurities is desired. As used herein, the terms “fluid” and “liquid” will be used interchangeably to refer to the material being flowed through the device and being frozen into comestibles. Because water is the chosen fluid to be frozen in many embodiments, the term “water” will be frequently used also; however, this use of the term “water” should not be considered limiting for the reasons stated herein. For similar reasons, the use of the term “ice” to refer to the chosen liquid when frozen should also not be considered limiting either.
In some embodiments, the ice created by the systems and devices described herein may have one or more of the following characteristics: clear, relatively free of impurities, relatively free of gas bubbles, relatively free of dissolved gasses, and/or cracking, may or may not have inclusions (e.g., flowers, liquor, food, etc.), etc. Such characteristics shall not be viewed as limiting in any way.
In some embodiments, water or liquid used to make the clear ice may be deaerated (e.g., gas sweeps, via vacuum, etc.), degassed, purified (e.g., sediment filtered, activated carbon block filtered, granular activated carbon filtered, reverse osmosis filtered, distilled, passed over an ion exchange column, treated with ultraviolet light, ultrafiltered, activated alumina filtered, ionized, etc.), or otherwise treated before being used to make clear ice. The water or liquid may be from a private well, a municipality, groundwater source, reservoir, etc.
Systems and Devices
The device functions to produce clear ice. The device is used for the production of clear ice in any situations where transparent ice is desired, such as for consumption in cocktails and other beverages but can additionally or alternatively be used for any suitable applications where a liquid material is frozen. Described broadly for many embodiments, the device generally provides at least one elongate trough or flume in thermal communication with one or more reservoirs or lines of circulating coolant or one or more cooling apparatuses (e.g., cooling plate, element, etc.). A flow of fluid (e.g., water) is provided down at least a portion of the length of the elongate trough during a freezing operation of the device. Clear ice forms on the surface walls of the trough, growing in thickness and filling up to a certain height in the elongate trough, according to various predetermined parameters described herein. In many embodiments, the speed of water (as either laminar or turbulent flow) through the elongate trough can be critical for the formation of clear ice by driving out air bubbles from the ice forming surface. In some embodiments, the device provides a flow of water having a velocity of at least about 0.09 m/s (about 0.3 ft/s) throughout the length of the elongate trough 108. In other embodiments, the velocity of the water is at least about 0.15 m/s (about 0.5 ft/s). In still other embodiments, the velocity of the water is at least about 0.21 m/s (about 0.7 ft/s). Once an ingot of ice has been generated within the at least one elongate trough, the freezing operation can be stopped, allowing for the collection of the ice ingot. The generated ice ingot can be subsequently modified to produce a variety of aesthetically pleasing comestibles. As used herein, the terms “elongate trough” and “flume” are considered synonymous and can be used interchangeably throughout.
In many embodiments, the devices and methods presented herein allow for the generation of clear ice at a rate superior to existing techniques. In some embodiments, the devices and methods herein can generate clear ice at a speed of at least about 7 mm/hr measured as linear height of accumulated clear ice on any given point of a surface wall of a trough per unit time. In another embodiment, the devices and methods herein can generate clear ice on a given point at a speed of at least about 24 mm/hr. Furthermore, in the devices and methods described herein, ice grows in multiple directions, thereby effectively halving the thickness of ice through which heat must flow to generate new ice. This provides a dramatic advantage in speed over preexisting technologies that can only grow ice in a single direction. For example, a Clinebell CB3002XD produces ice in one direction at a speed of about 3.0 mm/hr while a CFBI PIM0206 produces ice in one direction at about 6.4 mm/hr. With some embodiments of the devices and methods described herein achieving a total ice formation rate of about 1.27 cm to about 2.54 cm per hour, the disclosure herein can more than double the rate of clear ice formation over these other devices.
As shown in
In embodiments wherein each elongate trough 108 has a continuous arcuate shape, the elongate trough can be considered to be defined by a singular flume surface wall 106. However, in many embodiments, an elongate trough 108 can be defined by three flume surface walls 106: two side flume surface walls 106b and 106c and one base flume surface wall 106a. The particular shape and contour of the one or more flume surface walls 106 of each elongate trough 108 define a cross-sectional shape or profile for that elongate trough 108. Various cross-sectional shapes are presented herein. In various embodiments wherein the housing 102 defines more than one elongate trough 108, each elongate trough 108 can have the same cross-sectional profile or a different cross-sectional profile than another elongate trough of the same device 100. In certain embodiments, a single elongate trough 108 can be shaped such that its cross-sectional shape changes over the length of the elongate trough 108. In some of these embodiments, having such a variable shape could assist with the removal of the produced ingot of ice from the device 100. As described herein, the cross-sectional shape of an elongate trough 108 of the device 100 can greatly influence the clarity and therefore the quality of the produced clear ice in many embodiments.
Furthermore, in some embodiments, the flume surface walls 106 of an elongate trough 108 comprise a single, uniform material. In some embodiments, the flume surface walls 106 comprise aluminum, stainless steel, copper, or another thermally conductive material or thermally conductive metal or alloy. In additional embodiments, the flume surface walls 106 comprise material that is food-safe or otherwise known to be non-toxic when used in the production of comestibles. In other embodiments, various subsections of the flume surface walls 106 can comprise a material different from other subsections of the flume surface walls 106 of the same elongate trough 108. For example, in some embodiments, portions of the flume surface walls 106 outside the intended area of ice formation (i.e., outside the ice-forming zone and within the fluid overflow zone, see
In additional embodiments, an elongate trough 108 can have a minimum width 124 measured from between the two closest points of opposite side surface walls 106 of about 2.54 cm to about 30.48 cm (about 1 inch to about 12 inches). In some embodiments, an elongate trough 108 can have a minimum width 124 of about 2.54 cm to about 25.4 cm (1 inch to about 10 inches). In other embodiments, an elongate trough 108 can have a minimum width 124 of about 2.54 cm to about 12.70 cm (about 1 inch to about 5 inches). In certain embodiments, the at least one elongate trough 108 can have a minimum width 124 of about 7.62 cm (about 3 inches).
In some embodiments, the at least one elongate trough 108 can have a length 120 of at least about 45.72 cm (about 18 inches). In other embodiments, the at least one elongate trough 108 can have a length 120 of at least about 91.44 cm (about 3 feet). In still further embodiments, the at least one elongate trough 108 can have a length 120 of about 1.22 m to about 3.66 m (about 4 to about 12 feet). In other embodiments, the at least one elongate trough 108 can have a length 120 of about 1.22 m to about 2.44 m (about 4 feet to about 8 feet). In other embodiments, the at least one elongate trough 108 can have a length 120 of about 91.44 cm to about 2.13 m (about 3 feet to about 7 feet). In further embodiments, the at least one elongate trough 108 can have a length 120 of about 1.83 m (about 6 feet). In certain embodiments, the at least one elongate trough 108 can have a length 120 of about 2.03 m (about 80 inches). In some embodiments, the at least one elongate trough 108 can have a length 120 of about 45.72 cm to about 3.66 m (about 18 inches to about 12 feet). In various embodiments wherein the housing 102 defines a plurality of elongate troughs 108, each trough can have the same or different length than another elongate trough 108 of the device 100.
Returning to
In some embodiments, the at least one fluid intake 112 and at least one drain 114 are configured to provide a flow of water such that the entire volume defined within the elongate trough 108 is filled with moving water except for the portion occupied by the growing mass of clear ice during a freezing operation of the device 100. In some embodiments, the at least one fluid intake 112 and drain 114 provide fluid (e.g., water) having a velocity of at least about 0.09 m/s (about 0.3 ft/s) throughout the length of the elongate trough 108. In other embodiments, the velocity of the water is at least about 0.15 m/s (about 0.5 ft/s). In still other embodiments, the velocity of the water is at least about 0.21 m/s (about 0.7 ft/s). In other embodiments, the at least one fluid intake 112 and at least one drain 114 are adapted to provide a flow of water such that the entire volume defined within the ice-forming zone 112b and a portion of the fluid overflow zone 112a is filled with moving water except for the portion occupied by the growing mass of clear ice during a freezing operation of the device 100.
The at least one fluid intake 112 and/or drain 114 are fluidly connected to a fluid supply such as a water supply (not shown) and any other additional equipment appreciated by those of skill in the art to allow for a substantially continuous flow of fluid to the at least one elongate trough 108 during a freezing operation of the device 100. In some embodiments, the fluid supply provides a substantially continuous stream of new fluid to the device throughout the entire freezing operation; in other embodiments, the fluid supply can recirculate at least a portion of a starting volume of fluid throughout the freezing operation. In certain embodiments, de-aerated water can be supplied or recirculated to the device 100 from the fluid supply.
In many embodiments, an appropriate velocity of fluid into the at least one elongate trough 108 can be critical for the formation of clear ice as opposed to cloudy or opaque ice. In various circumstances, quickly freezing a volume of still or slow-moving water can trap air bubbles and impurities within the ice, resulting in a hazy appearance. However, in addition to other advantages of the device 100 described herein, the device's 100 flow of water can mitigate the trapping of air bubbles within the ice during the freezing process, even at high rates of freezing. In some embodiments, the flow of water can also be turbulent flow. Therefore, the device 100 as disclosed herein is capable of producing a solid ingot of clear ice of sufficient quality faster than other known methods.
In some embodiments, the flow rate of fluid remains constant over the whole duration of a freezing operation of the device 100. In other embodiments, the flow rate of the fluid varies over a freezing operation of the device 100. In some embodiments, periods of flow reversal may occur in which the fluid intake 112 becomes the fluid drain 114, and the fluid drain 114 becomes the fluid intake 112.
At least one internal cooling cavity 104, defined by housing 102, is in thermal communication with the flume surface walls 106 across many embodiments, thereby establishing the heat transfer necessary for the formation of clear ice in the at least one elongate trough 108. In some embodiments, the at least one internal cooling cavity 104 is a singular internal cooling cavity 104. In other embodiments, the at least one internal cooling cavity 104 is a plurality of cooling cavities that are in thermal communication with various subsets of flume surface walls 106 and/or portions of flume surface walls 106. In some embodiments for an elongate trough 108 having a base flume surface wall 106a and two side flume surface walls 106b and 106c, each flume surface wall 106a, 106b, and 106c are each in thermal communication with a unique internal cooling cavity 104 defined by the housing 102. Across various embodiments, the at least one internal cooling cavity 104 can include various structures and architectural features within in order to facilitate an even flow and distribution of coolant within it. In some embodiments, these structures can include but are not limited to mesh grates.
During a freezing operation of the device 100, the at least one internal cooling cavity 104 can be at least partially filled by a circulating coolant sufficient to lower the temperature of at least a portion of one or more flume surface walls 106 to about 0° C. or colder. In another embodiment, the at least one internal cooling cavity 104 can be at least partially filled by a circulating coolant sufficient to lower the temperature of at least a portion of one or more flume surface walls 106 to about −45° C. In still other embodiments, the at least one internal cooling cavity 104 can be at least partially filled by a circulating coolant sufficient to lower the temperature of at least a portion of one or more flume surface walls 106 to about 0° C. to about −20° C. In further embodiments, the at least one internal cooling cavity 104 can be at least partially filled by a circulating coolant sufficient to lower the temperature of at least a portion of one or more flume surface walls 106 to about −2° C. to about −20° C. In still further embodiments, the at least one internal cooling cavity 104 can be at least partially filled by a circulating coolant sufficient to lower the temperature of at least a portion of one or more flume surface walls 106 to about −2° C. to about −35° C. In some embodiments, the internal cooling cavity 106 and its contained circulating coolant are adapted to hold at least a portion of one or more flume surface walls 106 to a constant temperature during a freezing operation of the device 100. In other embodiments, the internal cooling cavity 106 and its contained circulating coolant are adapted to provide a variable temperature to at least a portion of one or more flume surface walls 106 during a freezing operation of the device 100 that changes according a predetermined temperature schedule.
In many embodiments, the volume of the at least one internal cooling cavity 104 can be minimized and/or insulated from portions of the housing 102 that are not flume surface walls 106 in order to minimize the amount of coolant needed to sufficiently cool the flume surface walls 106 for the generation of ice. As one of skill in the art will appreciate, the one or more cooling cavities may be replaced with other cooling apparatuses (e.g., cooling plate, cooling elements, etc.), without departing from the scope of the present disclosure.
One of skill in the art will appreciate that a variety of coolants can be used including, but not limited to, propylene glycol, ethylene glycol, and brine. For the circulation of coolant, the at least one internal coolant cavity 104 is fluidly connected to a coolant circulation system (not shown) via at least one coolant intake 116 and at least one coolant outtake 118. As illustrated in the embodiment of
The embodiment of the device 100 of
In various embodiments, the device 100, optionally, further comprises a lid 120 that comprises a substrate that removably couples or attaches to the housing 102 to enclose and thermally insulate the at least one elongate trough 108. As illustrated in the embodiment of
In other embodiments, the lid 120 as described above can be adapted to fit onto other clear ice makers including but not limited to a Clinebell Equipment CB300X2D or a Clinebell Equipment CI-4. Such an adapted lid 120 in these embodiments would provide similar ease of introduction of inclusions to clear ice generated by these alternate devices.
In still further embodiments, the inclusion holders 122 can be adapted to position an item within an elongate trough 108 without the use of a lid 120. In these embodiments, the inclusion holders 122 can be suspended over uncovered elongate troughs 108 by a scaffold or frame, or they can be integrated in a position on a top edge of the housing 102 itself.
Coolant outlet and inlet lines 308 connect the internal cooling cavities (not shown) to a coolant supply (not shown) that chills and circulates coolant through the device 300 during a freezing operation. As discussed herein, various coolants can be employed, including, but not limited to, propylene glycol, ethylene glycol, and brine. In some embodiments, the coolant supply and/or mechanical components of the coolant outlet and inlet lines 308 can regulate at least one of coolant temperature and flow rate into the plurality of internal cooling cavities either individually or collectively. In alternative embodiments, the internal cooling cavities can be replaced by other cooling sources, such as cold plates, condensers, evaporators, etc.
The device 300 can also comprises a lid 320, in some embodiments. A lid, when constructed of thermally insulating materials, can assist in maintaining a uniform and adequately cool temperature within the device 300 that can contribute to the generation of clear ice along all the flume surface walls of all elongate troughs 304. In the embodiment shown in
In the embodiment of
In many embodiments, a fluid intake manifold 600a further comprises a cavity divider 606a. The cavity divider 606a is a rigid or semi-rigid but porous insert that mitigates the formation of a circular current of fluid within the manifold cavity 601a as fluid makes its way from the fluid inlet pipes 602a to the fluid entry portals 604a. In many embodiments, the cavity divider 606a has a porosity of 5% to 75% open area. In other embodiments, the cavity divider 606a has a porosity of 10% to 50% open area. In further embodiments, the cavity divider 606a has a porosity of 15% to 30% open area. In the embodiment of
In many embodiments, a drain manifold 600b further comprises a cavity divider 606b. The cavity divider 606b is a rigid or semi-rigid but porous insert that mitigates the formation of a circular current of fluid within the drain manifold cavity 601b as fluid makes its way from the fluid exit portals 604b to the drainage pipes 602b. In many embodiments, the cavity divider 606a has a porosity of 5% to 75% open area. In other embodiments, the cavity divider 606a has a porosity of 10% to 50% open area. In further embodiments, the cavity divider 606a has a porosity of 15% to 30% open area. In the embodiment of
In many embodiments, the flow straightener insert 700 serves to organize the flow of fluid into or out of an elongate trough 750. As a particular range of velocities can be critical for the development of clear ice at speeds superior to existing technologies in some embodiments, the flow straightener insert 700 can prevent or mitigate the formation of swirling vortexes of fluid within the elongate trough 750. Such vortexes can generate areas within the elongate trough 750 where fluid is moving too slowly, thus leading to cloudy sections within the generated ingot of clear ice.
The device 1100 comprises a removable lid 1110 depicted in
In further embodiments, the lid 1110 can further comprise one or more inclusion holders 1118 that extend through the lid 1110 into the ice-making volume defined by the elongate trough 1104. In the embodiment of
In many embodiments of
In many embodiments of
The embodiments of possible cross-sectional shapes for an elongate flume depicted in
For some embodiments, having a θ, θ1, and θ2 greater than about 0° can be valuable to the production of clear ice during a freezing operation of the device. In certain embodiments of the device, clear ice forms on at least a portion of the base flume wall and the two side surface walls (as shown in
In some embodiments with certain flow rates, angling one or more side surface walls of an elongate trough can avoid or mitigate the above concerns. By sloping their planes of ice formation slightly away from each other, the device can, in certain embodiments, instead direct a more gradual filling in of ice from the bottom of a “v-shaped” or “u-shaped” valley rather than suddenly abutting two vertical planes of clear ice into each other. In many embodiments, sloping the side surface walls does slightly lengthen the required time to produce an ingot of clear ice compared to an analogous elongate trough having vertical walls (see Example 1, below). In other embodiments, the device can generate an ingot of clear ice using elongate troughs having vertical side surface walls by intentional control of flow rate and temperature of the three side walls.
Once an ingot of ice has been produced, such as by an embodiment of the device of the above figures, it can be further processed to efficiently generate a plurality of comestibles with aesthetically pleasing shapes and/or additional properties as described herein.
Methods
As shown in
The method 1600 includes for providing a device for making clear ice according to block S1602. The device for making clear ice can be any of the embodiments of devices described elsewhere herein and depicted in the various figures above.
Next, at step S1604, the method 1600 optionally includes for positioning at least one item in at least one inclusion holder. As described above, the inclusion holders can secure an item within the space defined by an elongate trough during a freezing operation of the device such that the one or more items will be inside the ingot of clear ice upon completion of the freezing cycle. These inclusion holders, such as skewers, clips, or clamps, can be affixed to a lid of the device or elsewhere as described above.
At Step S1606, the method 1600 then includes providing a flow of water down at least one elongate trough. In many embodiments, the flow of water is provided to the elongate trough by at least one fluid intake valve positioned in the housing of the device or in the lid of the device and drained by at least one drain valve as described above. In other embodiments, the flow of water can be provided by other means appreciated by those of skill in the art. A sufficient flow rate of water is required in order to exclude air bubbles and impurities from the growing layer of clear ice on at least one flume surface wall during a freezing operation of the device in many embodiments.
At Step S1608, the method next includes cooling at least a portion of at least one flume surface wall of the at least one elongate trough to produce a growing layer of clear ice on the at least a portion of at least one flume surface wall. In many embodiments, this cooling can be performed by the circulation of coolant through at least one internal coolant cavity as described above. Also as discussed above, coolant is provided to the device by a coolant supply system via at least one coolant intake valve and is cycled out by at least one coolant outtake valve in many embodiments. In alternate embodiments, Step S1608 includes for providing and utilizing an alternative cooling apparatus including but not limited to cold plates, compressors, etc. for the generation of the temperatures needed to produce clear ice on the one or more flume surface walls.
In some embodiments, the at least a portion of at least one flume surface wall is cooled to a temperature of about 0° C. or less. In another embodiment, the at least a portion of at least one flume surface wall is cooled to about −45° C. In still other embodiments, the at least a portion of at least one flume surface wall is cooled to about 0° C. to about −20° C. In further embodiments, the at least a portion of at least one flume surface wall is cooled to about −2° C. to about −20° C. In further embodiments, the at least a portion of at least one flume surface wall is cooled to about −2° C. to about −35° C. In some embodiments, the at least a portion of at least one flume surface wall is adapted to hold a constant temperature during a freezing operation of the device. In other embodiments, the at least a portion of at least one flume surface wall is adapted to provide a variable temperature during a freezing operation of the device that changes according a predetermined temperature schedule.
In many embodiments, the cooling of step S1608 involves gradually decreasing the temperature of the flume surface walls over time. In many embodiments, a gradual decrease in temperature allows the device to overcome the inherent insulating properties of the ice as it forms. Because ice freezes directionally outwards from the flume surface walls that relay the chilled temperatures to the flow of water as shown in
At optional Step S1610, the method 1600 provides for retracting the at least one inclusion holder. In many embodiments, the at least one inclusion holder should be retracted before the growing layer of clear ice comes into contact with the inclusion holder. In many embodiments, the at least one inclusion holder is retracted after a sufficient accumulation of ice has formed within the elongate trough such that the item remains at least partially embedded in the accumulation of ice upon retraction of the at least one inclusion holder. In some embodiments, the at least one inclusion holder is retracted by mechanical means. In some of these embodiments, the at least one inclusion holder is retracted mechanically after a certain duration of time of a freezing operation has passed or after a predetermined volume of ice has formed. In other embodiments, the at least one inclusion holder is retracted manually. In various embodiments wherein there are a plurality of inclusion holders, each or a subset can be collectively retracted simultaneously or individually at different times and/or at different volumes of formed ice.
Regardless of the presence or operation of any inclusion holders, the method 1600 allows for the flow of water and the circulation of coolant until a desired quantity of clear has formed within the at least one elongate trough. The resulting ingot of clear ice will have a length and cross-sectional shape determined by or related to those of the corresponding elongate trough in which it formed. Once the ingot of ice has formed to a predetermined or desired height or volume, the flow of water and circulation of coolant can be ceased, and the ingot of ice can be removed by a variety of means appreciated by those of skill in the art, including but not limited to letting the ingot slightly melt and removing it by mechanical means. In some embodiment, the slight melting can be provided by a circulation of warmer coolant in the at least one internal cooling cavities. In other embodiments, one or more side surface walls may further include one or more heating elements or heating means, such that an external surface of the ice ingot may be melted to facilitate ice removal from the device. In some embodiments, the ingot of ice can be removed vertically by lifting it out of an elongate trough, but in other embodiments, the ingot of ice can be removed horizontally by sliding it out of the elongate trough through an openable or removable end wall. In some embodiments, the device is adapted such that the ingot of ice adheres to a surface of the lid such that removing the lid additionally removes the ingot of ice with it.
In some embodiments, a method for forming clear ice includes: providing a device, for example, any of the above embodiments; optionally inserting a skewer or clip through the lid, the skewer or clip being coupled to an item or configured to release a fluid into a cavity in the ice (e.g., skewer defines one or more apertures); circulating, using the fluid inlet and outlet valves, a fluid in the elongate trough; optionally varying overtime one or both of: a temperature of the cooling apparatus or source or a fluid flow, through the fluid inlet valve, as a percentage of max flow; and optionally retracting the skewer or clip when the ice formation encases at least a portion of the item.
As shown above, in some embodiments, temperature of the flume surface walls (hereinafter, “surface temperature”) is varied (e.g., 0° C. and about −25° C. or any of the ice making methods described elsewhere herein); in other embodiments, the flow rate of water (hereinafter, “water flow rate”) is varied (e.g., percentage of max water flow between about 5% and about 100% or any of the ice making methods described elsewhere herein). In some embodiments, both surface temperature and water flow rate are varied. In some embodiments, neither temperature nor flow rate are varied. In various other embodiments, the temperature of the water flowing through the elongate troughs (hereinafter “water temperature) can be varied solely or in addition to the other parameters named above.
In some embodiments, the device is configured to receive an inclusion holder (e.g., a skewer or clip), such that the method includes inserting the skewer or clip and optionally retracting the skewer or clip at a predetermined time. The predetermined time is dependent on a type of item coupled to the skewer, dependent on a volume of the elongate trough, a random predetermined time, or combination thereof. In some embodiments, ice formation is monitored via a sensorized mold and/or skewer/clip such that the skewer or clip is removed or retracted based on a progress of ice formation. The method may optionally include releasing the ice from the elongate trough with the item encased therein, for example via gravity, manual removal, automatic removal (e.g., ejector pin, air, hydraulics, etc.). In some embodiments, the method optionally includes sealing a lid to the device, for example via a gasket, pressure seal, screw type seal, etc.
Further, as shown in
Further, as shown in
The methods of the preferred embodiment and variations thereof can be embodied and/or implemented at least in part as a machine configured to receive a computer-readable medium storing computer-readable instructions. The instructions are preferably executed by computer-executable components preferably integrated with the system and one or more portions of the processor on a computing device in communication with various components of the device for producing clear ice, such as but not limited to its various valves. The computer-readable medium can be stored on any suitable computer-readable media such as RAMs, ROMs, flash memory, EEPROMs, optical devices (e.g., CD or DVD), hard drives, floppy drives, or any suitable device. The computer-executable component is preferably a general or application-specific processor, but any suitable dedicated hardware or hardware/firmware combination can alternatively or additionally execute the instructions.
As used in the description and claims, the singular form “a”, “an” and “the” include both singular and plural references unless the context clearly dictates otherwise. For example, the term “trough” may include, and is contemplated to include, a plurality of troughs. At times, the claims and disclosure may include terms such as “a plurality,” “one or more,” or “at least one;” however, the absence of such terms is not intended to mean, and should not be interpreted to mean, that a plurality is not conceived.
The term “about” or “approximately,” when used before a numerical designation or range (e.g., to define a length or pressure), indicates approximations which may vary by (+) or (−) 5%, 1% or 0.1%. All numerical ranges provided herein are inclusive of the stated start and end numbers. The term “substantially” indicates mostly (i.e., greater than 50%) or essentially all of a device, substance, or composition.
As used herein, the term “comprising” or “comprises” is intended to mean that the devices, systems, and methods include the recited elements, and may additionally include any other elements. “Consisting essentially of” shall mean that the devices, systems, and methods include the recited elements and exclude other elements of essential significance to the combination for the stated purpose. Thus, a system or method consisting essentially of the elements as defined herein would not exclude other materials, features, or steps that do not materially affect the basic and novel characteristic(s) of the claimed disclosure. “Consisting of” shall mean that the devices, systems, and methods include the recited elements and exclude anything more than a trivial or inconsequential element or step. Embodiments defined by each of these transitional terms are within the scope of this disclosure.
The examples and illustrations included herein show, by way of illustration and not of limitation, specific embodiments in which the subject matter may be practiced. Other embodiments may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. Such embodiments of the inventive subject matter may be referred to herein individually or collectively by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventive concept, if more than one is in fact disclosed. Thus, although specific embodiments have been illustrated and described herein, any arrangement calculated to achieve the same purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description.
As described above, the cross-sectional shape of the elongate trough can have an impact on both the clarity of clear ice formed as well as the time required of a freezing operation of the device to generate a particular volume of clear ice in many embodiments. Because heat flow through ice is directly proportional to 1/W2 (wherein W is the distance to the center of the flume at a given height), the time required for the formation of a certain volume of ice can be approximated by the following Formula 1:
Wherein Lv is the Latent Heat of Fusion of the liquid (e.g., water), K is the thermal conductivity of ice, and ΔT is the temperature differential experienced across the medium in which heat is flowing.
In applying too great of a temperature differential across a length of a solid material, cracks can form in ice, which negatively affects the visual clarity of ice. For example, if one ramps the freezing temperature down too quickly, the newly frozen ice will form cracks as it suddenly freezes. Ramping the temperature down, however, can be quite valuable during a freezing operation of various ice makers, including embodiments of the device of
Therefore, for the generation of a high-quality clear ice product, this stress must be avoided during the ice formation process. The stress (a) experienced by ice can be calculated by the following Formula 2:
Wherein α is the coefficient of thermal expansion for ice (5.0×10−5° C.−1), E is Young's modulus, and ΔT is the temperature differential experienced across the medium in which heat is flowing. Empirically, it is known that ice can withstand about 1 MPa of stress under this calculation before cracking.
However, as long as the conditions are not so stressful as to crack the ice, the ice naturally “relaxes” over time and reduces its experienced stress (this process is also known as creep, where solids materials near their melting point undergo physical deformations; this reduces the likelihood of cracking). The time tλ, required to relax a proportion of stress λ (the relaxation factor) from a material can be calculated by the following Formula 3:
Wherein n is a first material constant for ice (a value of 3, unitless), A0 is a second material constant for ice (1.36×109 MPa−3 s−1), σ is the starting stress of the material in MPa, E is Young's Modulus, Q is the activation energy (78,000 Jmol−1K−1), R is the universal gas constant, and T is the absolute temperature. Ice accumulation and relaxation can occur simultaneously as long as the experienced conditions do not apply a stress greater than 1 MPa at any point during the cycle. Therefore, the temperature of a cold surface for the generation of ice, such as a flume surface wall, can be ramped down as long as its schedule allows for sufficient relaxation against the gaining stress.
Because the accumulation of clear ice within an elongate trough of the device as described herein generally occurs in a multidirectional manner (e.g.,
Wherein Aouter is the surface area of the outer cylindrical surface and Ainner is the surface area of the inner cylindrical surface. The surface area of a cylindrical shape can be calculated by A=2πrL wherein r is the radius of the cylinder and L is the length of the cylinder.
Wherein k is the thermal conductivity of the material, A is A1m, ΔT is the change in temperature across the system, and Δr is the change in radius for the cylinder.
This application claims the priority benefit of U.S. Provisional Application No. 63/276,506, filed on Nov. 5, 2021, and the priority benefit of U.S. Provisional Application No. 63/116,453, filed on Nov. 20, 2020, the disclosures of which are herein incorporated by reference in their entireties.
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