Patent Application
20240280305
The present invention generally relates to the field of ice production, specifically to an apparatus and method for producing large, transparent ice cubes. These ice cubes are characterized by their lack of visible bubbles, crystallization, chips, cracks, and milky appearance, and are suitable for human consumption. The invention particularly addresses the need for an energy-efficient system capable of automatically dispensing premium ice cubes that possess a Mohs hardness of 2-6, making them durable and long-lasting when used in beverages. The invention also encompasses novel methods for cutting these large transparent ice cubes into smaller, non-spherical shapes without inducing chipping or cracking, as well as the use of food-grade materials to ensure compliance with U.S. food regulations.
The quest for creating the perfect transparent ice cube has been fraught with challenges, particularly in the context of mass production for consumer use. Traditional methods of ice production have often fallen short in delivering ice cubes that meet the high standards of clarity and purity demanded by consumers and high-end establishments. These consumers seek large, flawless ice cubes that are devoid of bubbles, cloudiness, cracks, and any milky appearance, which can otherwise detract from the visual appeal and taste experience of beverages.
Existing ice-making technologies have struggled to control the freezing process adequately, resulting in ice cubes with visible imperfections. These imperfections are often due to the entrapment of air and impurities within the ice as it freezes, a common issue that prior art has not effectively addressed. Moreover, the process of cutting larger blocks of ice into smaller cubes has been problematic, with a tendency for the ice to chip and crack, thus compromising the integrity and appearance of the final product.
Prior art, such as the teachings of Lawrence in Patent Cooperation Treaty Patent Application PCT/US2007/084787 filed on Nov. 15, 2007, which is hereby incorporated by reference in its entirety, discusses the concept of clear ice and suggests methods for its production. However, Lawrence's disclosure reveals inherent limitations and misunderstandings in the approach to creating truly transparent ice cubes. For instance. Lawrence's method does not adequately prevent the formation of visible bubbles within the ice, nor does it suggest a means to maintain thermal communication between the refrigeration elements and the water during the freezing process, which is crucial for achieving a high-quality transparent ice cube with the desired hardness. Additionally. Lawrence incorrectly attributes the cause of cloudiness in ice to dissolved gases forming bubbles, rather than the actual water chemistry involved.
The prior art also fails to provide a solution for the precise cutting of transparent ice cubes into smaller, non-spherical shapes without inducing damage. The lack of a method to cut ice cubes with a specific hardness range, such as a Mohs hardness of 2-6, without chipping or cracking, represents a significant gap in the prior art. The prior art's deficiency in addressing the precise cutting of transparent ice cubes into smaller, non-spherical shapes without causing damage is a notable shortcoming. Transparent ice cubes, due to their clarity and density, possess unique physical properties that require careful handling during the cutting process. Cutting transparent ice cubes outside of this specified hardness range can lead to several problems. For instance, ice cubes with a Mohs hardness less than 2 may be too soft, causing them to fracture or crumble under the pressure of cutting tools, leading to irregular shapes and a loss of the aesthetic appeal that is essential for applications where presentation is important, such as in culinary settings or in luxury beverages. On the other hand, ice cubes with a Mohs hardness greater than 6 may be excessively hard, which can dull cutting blades quickly, increase the force required for cutting, and potentially result in the generation of stress fractures within the ice cube. These fractures can propagate through the ice cube, causing it to shatter unpredictably, which not only wastes material but also poses a safety risk to the operator.
Cutting ice within the specific hardness range mentioned above also poses particular challenges. For example, cutting blade wobble may occur during the cutting process of ice featuring a Mohs hardness of 2-6. Devices such as that disclosed in U.S. patent application Ser. No. 18/253,706 filed on Nov. 19, 2021, which is hereby incorporated by reference in its entirety, cause chipping of the ice. As those in skilled in the art would appreciate, the aesthetics associated with ice that has been chipped such as the ice portions created in association with the invention disclosed in the '706 patent application mentioned immediately above are of a much less desirable quality than ice portions that are created lacking any visible cracks and any visible chips. It remains crucial to reduce blade wobble for maintaining precision during the cutting process, a problem that remains to be solved. Excessive wobble can lead to uneven cuts and can increase the likelihood of inducing stress points within the ice cube, which can later result in cracks or chips. By controlling the blade's stability, the invention ensures that each cut is consistent and that the resulting smaller, non-spherical ice cubes are free from visible defects, thereby maintaining the quality and value of the final product.
The prevention of visible crystallization within an ice cube's center remains a persistent challenge in association with ice cutting and production methodologies known in the prior art. This issue is central to the quality and aesthetic appeal of transparent ice cubes, as crystallization can manifest as cloudiness or a milky appearance, detracting from the desired clarity. The formation of visible crystallization is a natural occurrence when water transitions from a liquid to a solid state, as water molecules tend to align in a crystalline structure. However, in the context of transparent ice cube production, such crystallization is undesirable. It typically arises due to uncontrolled freezing conditions, where the water freezes from multiple directions, allowing air and impurities to become trapped within the ice. These imperfections disrupt the uniformity of the ice structure, leading to the appearance of white, opaque areas that are visually unappealing.
The industry has long sought methods to produce perfectly clear ice cubes, where the entire cube. including the center, is free from such crystallization, thereby achieving a level of purity and transparency that is both visually striking and indicative of higher quality. It remains desirable therefore to address this problem by introducing a novel approach to the freezing process that mitigates the factors contributing to visible crystallization, thereby allowing for the production of transparent ice cubes with enhanced clarity. Concerns associated with the movement of refrigeration piping in ice-making systems.
Historically, the industry has been cautious about implementing designs that involve the dynamic movement of refrigeration components due to the increased risk of wear and tear. Such movement has been known to result in the degradation of piping integrity, leading to premature system failures and the potential for refrigerant leaks. These issues have been significant obstacles in prior art attempts, as leaks not only compromise the efficiency and performance of the refrigeration system but also pose environmental and safety risks. The challenge remains to develop a refrigeration system that can withstand the mechanical stresses of movement without succumbing to the common pitfalls of component fatigue and leakage, thereby ensuring reliable and sustained operation for the production of high-quality ice cubes.
Additionally, the Kirkpatrick reference, U.S. Pat. No. 2,414,264 filed on April 3, 1945, which is hereby incorporated by reference in its entirety, presents its own set of problems and challenges in the realm of transparent ice cube production. Kirkpatrick purports to provide an apparatus for making crystal clear ice cubes, yet the method outlined therein fails to incorporate a critical aspect of ice cube production—unidirectional freezing. Without this key process, it is scientifically implausible for Kirkpatrick's apparatus to produce truly transparent ice cubes. The absence of unidirectional freezing leads to the formation of ice with suboptimal clarity, as it allows for the inclusion of visible crystallization within the ice. This lacking aspect in the Kirkpatrick reference underscores the difficulty in achieving the high standard of transparency required for premium ice cubes and highlights the necessity for an improved method that addresses the shortcomings of the prior art.
The prior art also includes varying characterizations of what constitutes “clear ice.” In particular. Lawrence provides a definition of “clear ice” allowing for a certain degree of visible internal imperfections, such as bubbles and cloudiness, up to approximately 25% by volume. This tolerance for imperfections would not meet more stringent standards, which aim for ice cubes that are devoid of visible crystallization, visible bubbles, and visible cracks, ensuring a higher level of clarity. Moreover, the methods disclosed by Kirkpatrick and Lawrence do not guarantee a high level of uniform transparency throughout the ice cube, particularly at the center, which is the most challenging area to maintain clarity in association with ice production and handling. The creation of transparent ice to a higher standard than that reflecting the lacking definition of “clear ice” present in the Lawrence reference therefore remains a challenge to be solved.
Separately, BPA is a widely used industrial chemical found in the production of polycarbonate plastics and epoxy resins, which are common in various food packaging and storage solutions, and are used in association with ice processing aspects known in the prior art. Despite its prevalent use, BPA has become a subject of concern among consumers and food industry professionals due to potential health risks associated with its leaching into food and beverages. These concerns are amplified by studies suggesting that BPA exposure could lead to adverse health effects. The ongoing debate and emerging research have prompted calls for tighter restrictions on BPA usage, particularly in materials that come into contact with food, which remains a challenge in association with ice production and processing.
In light of these challenges, there is a clear need for an innovative approach to producing transparent ice cubes. Such an approach must overcome the limitations of prior art by ensuring controlled freezing that prevents imperfections, maintaining thermal communication throughout the freezing cycle, and enabling the precise cutting of ice cubes into various shapes and sizes without damage. Furthermore, the entire process must be conducted using food-grade materials to meet the stringent safety standards required for products intended for human consumption in the United States, which remains a problem to be solved.
The present invention relates to an energy-efficient method and apparatus for producing high-quality transparent ice cubes. The invention addresses the need for an ice cube maker that not only operates with enhanced energy efficiency but also produces large, premium ice cubes that are devoid of visible crystallization, bubbles, cloudiness, and internal visible cracks.
A key aspect of the invention is the utilization of a refrigeration system that includes a refrigeration pipe and a cavity in both thermal and mechanical communication with the pipe. The system is designed to vibrate or oscillate the refrigeration pipe, agitating the water in such a way that droplets jump significantly above the water surface, thereby mitigating the formation of visible bubbles within the ice cube.
The invention further comprises a method of freezing the water to form an ice cube that extends a substantial distance from the cavity wall, ensuring one-directional freezing. This method is critical for achieving the desired clarity and structural integrity of the ice cube. The ice cube produced weighs at least 3 ounces and includes a solid center portion that constitutes a significant percentage of the cube, which is free from visible imperfections.
Another innovative feature of the invention is the provision of water with a specific concentration of calcium carbonate, which is less than 180 milligrams per liter. This precise water composition contributes to the energy efficiency of the freezing process and the quality of the resulting ice cube.
The invention also contemplates the use of a refrigeration system that comprises multiple release openings and cavities, with each opening configured to direct water upwards into the cavity in a continuous flow. This configuration is instrumental in achieving the one-directional freezing of the water and the formation of an ice cube with a continuous, non-cubic shape.
Additionally, the invention provides for the optimization of various parameters, including the thickness of the cavity's bottom wall and the specific material ratios, to balance thermal transfer and structural stability of the ice cube. The detailed examples and comparative data underscore the improved thermal retention properties of the ice cubes produced by the claimed method, which melt slower than those produced by prior art methods.
The invention further details the complex interactions between the oscillation of the refrigeration pipe and the geometry of the cavity, leading to a unique water flow pattern that eliminates air pockets and results in clearer ice cubes. The technical advantages of the invention are not limited to ice cube quality but extend to the use of environmentally friendly refrigerants, offering a technical advantage over existing systems.
In summary, the present invention provides a novel and non-obvious method and apparatus for making transparent ice cubes that are structurally sound, clear, and energy-efficient, with a significant improvement over the prior art.
The present invention employs specific terminologies to define various aspects of the disclosed embodiments. The term “visible” refers to what can be seen by a human with 20/20 vision in both eyes without any visual enhancement when exposed to sunlight. An “ice cube” or “cube” is not confined to any particular size or shape and encompasses any shaped or sized ice, unless specifically claimed otherwise. The terms “includes” and “including” are intended to be inclusive, similar to the term “comprising.” The term “or” is also intended to be inclusive, meaning “A or B” should be interpreted as “A or B or both.”
Approximating language is used throughout the specification and claims to modify quantitative representations that could vary without changing the basic function they relate to. Such language includes terms like “about,” “approximately;” “substantially,” and “substantial,” which are not limited to the precise values specified. These terms may correspond to the precision of an instrument for measuring the value, potentially being within a ten percent margin.
A “motor” refers to any suitable drive motor and/or transmission assembly. A “scam” is defined as a line of junction formed between two surfaces. An “ice mold” is any structure in which water is frozen. The “center” of an “ice cube” refers to the absolute center point of the cube, unless claimed otherwise. A surface is “substantially flat” if it is 10 degrees of a level angle, and it “does not substantially tilt from side to side or tilt back and forth” if the movement occurs within 10 degrees of the starting angle. The term “spray” or “sprayed” means liquid that is propelled through the air in the form of tiny drops or fine mist. “Continuous water flow” indicates that water is always moving in a cavity. “Agitate,” “agitation,” or “agitated” refers to any water movement in a cavity; including water released upwards into a cavity.
The term “cryogenic” denotes a temperature range from −40° F. to −460° F. “Cryogenic compressor” or “cryogenic pump” refers to a compressor or pump that operates within this temperature range.
In the context of the invention, the term “frequency” refers to the rate at which vibration or oscillation occurs within a given time period, typically measured in cycles per second or Hertz (Hz). It is a measure of how often the water in the ice mold is agitated back and forth or up and down during the freezing process. Frequency is a relevant parameter in the process of making transparent ice cubes as it influences the movement of water molecules and the release of air bubbles trapped during the freezing process. However, frequency does not correlate directly to amplitude in the context of the invention, as frequency and amplitude are independent parameters that describe different characteristics of the agitation process used to create transparent ice cubes in the context of the invention. While frequency relates to the number of oscillations per second, amplitude pertains to the strength or extent of those oscillations. The invention's focus on amplitude, particularly the critical amplitude necessary to achieve transparent ice cubes, sets it apart from the less effective attempts and represents an innovative step in the field of ice cube production.
“Amplitude” refers to the measure of the intensity or the magnitude of the vibration or oscillation. It describes the height of the wave or the maximum extent of the vibration from the resting position. In the preferred embodiment, amplitude is specifically controlled to ensure that water droplets are propelled at least one-eighth of an inch above the water's surface. This precise control of amplitude is essential for preventing the entrapment of visible bubbles within the ice cube, which is a key aspect associated with the preferred embodiment of the invention. This amplitude is critical to the process associated with the preferred embodiment, as it ensures that the induced water droplets contribute to the one-directional freezing necessary for creating transparent ice cubes without the undesired crystalline structures. It is also a key factor in disrupting the molecular alignment that leads to visible crystallization. In the context of the preferred embodiment, “amplitude” may refer to the magnitude or intensity of the vibration or oscillation cycles applied to the water within the ice mold, which is distinct from “frequency,” the term that describes the number of vibration or oscillation cycles occurring per second. An aspect of one embodiment of the present invention is having the right amount of water amplitude to make a transparent ice cube with a center void of visible crystallization, void of a visible bubble. Unlike amplitude, frequency alone, regardless of its value, does not guarantee the desired elevation of water droplets in the context of embodiments of the invention; it is the amplitude's role to provide the necessary energy to propel the water droplets upward. Frequency is the number of vibration or oscillation cycles (usually per second) and amplitude refers to the violence of each cycle. Therefore, the invention carefully distinguishes between these two parameters, in the preferred embodiment optimizing both to achieve the highest quality of clear ice cubes.
For further clarity, frequency pertains to the rate at which vibrational cycles occur, quantified as cycles per second. However, the mere count of these cycles is insufficient to induce the necessary movement in water; it is the amplitude that provides the essential energy to propel water droplets. Without adequate amplitude, even with a high frequency, water droplets will not achieve the requisite elevation of at least ⅛th of an inch above the water's surface. Conversely, if the amplitude is excessively high, even at a low frequency such as 1 Hz, it could cause the water to eject from a standard 2-inch ice cube mold contemplated in association with an embodiment of the invention, unless a lid is employed to contain the water. Yet, such high amplitude could also result in the undesirable trapping of air bubbles within the forming ice cube in the context of embodiments of the invention. The optimal frequency in the context of the preferred embodiment is thus determined when nearly all water droplets are observed to leap the specified ⅛th of an inch, but no more than 6 inches, and then return to the water, ensuring the formation of a transparent ice cube without visible air bubbles.
As an example, the releasing of bubbles in water is not the science behind making a transparent ice cube but a result of the process. For further example, one may take a short glass and fill it half full of water that has no visible bubbles. The person may stick a finger in the water and stir. That person will observe that her finger movement creates visible bubbles such as any agitation means would if the agitation is vigorous enough. All bubbles can never be eliminated no matter how long the water is agitated. Agitation will therefore make bubbles appear in otherwise visually clear water. The key, in accordance with embodiments of the invention, is not releasing, or prevention of bubbles in water while the water freezes, which is impossible, but rather avoiding the trapping of visible bubbles in the ice cube when they are purposely induced into water through vibration or oscillation. In association with embodiments, the amplitude is such that substantially all of the water droplets, meaning at least 90% of the water droplets, jump, meaning each water droplet separates from the main mass of the water, at least one ⅛th of an inch vertically above a top surface of the water and less than 6 inches, and further substantially all of the water droplets, meaning at least 90% of the water droplets, drop and fall back into the water.
The distinction between frequency and amplitude is crucial in differentiating the invention from less optimal attempts present in the prior art. While such attempts are associated with methods of agitating water during the freezing process, it has been left to the present inventor to discover the critical amplitude required to achieve the desired level of transparency in ice cubes. In the context of the preferred embodiment, specificity regarding the amplitude necessary to prevent the formation of visible bubbles and crystallization within the center of the ice cube is a key differentiating aspect of the invention.
The preferred embodiment of the present invention not only recognizes the importance of frequency in the agitation process but also emphasizes the precise control of amplitude. The method associated with the preferred embodiment ensures that the agitation is vigorous enough to cause water droplets to jump above the water's surface, which is a key factor in producing transparent ice cubes devoid of visible imperfections. The criticality of the measured range of amplitude in association with the preferred embodiment cannot be overstated, as it is a pivotal factor in achieving the desired quality of transparent ice cubes. The preferred embodiment specifies that the amplitude of the water agitation must be such that water droplets are propelled at least one-eighth of an inch above the water's surface. This precise amplitude is essential for ensuring that air bubbles, which are naturally present in water, are released and do not become trapped within the forming ice cube. If the amplitude is too low, the water will not be agitated sufficiently to release these bubbles, resulting in ice cubes with visible imperfections, as is evidenced by prior art attempts. Conversely, if the amplitude is too high, it could lead to excessive turbulence, potentially causing the formation of a cloudy or milky appearance in the ice. Therefore, the specified amplitude range is critical for the process, as it directly influences the expulsion of air and impurities from the water, leading to the production of ice cubes with the highest level of clarity and structural integrity. This requirement for a specific amplitude range to achieve transparent ice cubes devoid of visible crystallization, clear bubbles, and cracks is a distinctive aspect of the invention that differentiates it from prior art and underscores its innovative approach to ice cube production.
The invention includes an embodiment that achieves the correct water amplitude to create a transparent ice cube with a center devoid of visible crystallization and bubbles. The amplitude is the intensity of the water movement, while in contrast the frequency is the rate of the movement. The process of creating transparent ice cubes involves adjusting the amplitude such that water droplets jump at least one-eighth of an inch above the water's surface, noting the frequency at which this occurs to establish the proper frequency for ice cube formation. A aspect of the preferred embodiment involves controlling the amplitude of water movement within the ice mold to achieve transparent ice cubes that are free from visible crystallization and bubbles. The amplitude, defined as the intensity of each cycle of water movement, is meticulously adjusted so that water droplets are propelled at least one-eighth of an inch above the water's surface. This precise manipulation of water amplitude is essential for the formation of transparent ice cubes in association with the preferred embodiment, as it prevents the entrapment of visible bubbles during the freezing process. The preferred embodiment's methodology is not focused on merely releasing bubbles from the water, which is an inevitable result of vigorous agitation, but rather on ensuring that these bubbles do not become trapped within the ice cube. To illustrate the concept for those skilled in the art and to aid in the practice of making the invention, consider the following example: Suppose a glass is filled to the midpoint with water that initially contains no visible bubbles. Upon stirring the water with a finger, one would observe the formation of visible bubbles, akin to the outcome produced by any sufficiently vigorous agitation method. This example is provided to help those skilled in the art understand the principles of agitation as they relate to the invention's process for creating transparent ice cubes. The preferred embodiment's approach ensures that, despite the natural occurrence of bubbles in agitated water, the critical amplitude is maintained such that these bubbles rise and are not encapsulated within the forming ice, resulting in a transparent ice cube devoid of visible imperfections.
Various embodiments of the invention comprise a cutting module. An aspect of the cutting module provides for the cutting of larger transparent ice cubes into smaller non-spherical ice cubes at a high feed rate or cut rate without causing cracks or chips. This embodiment is particularly distinct from cutting spherical ice or large soft blocks of cloudy ice into smaller pieces. The process of creating transparent non-spherical ice cubes in association with embodiments of the invention involves a delicate approach, as the inherent geometry of a sphere is easier to accomplish in the context of transparent ice, as a sphere shape facilitates the distribution stress evenly across its surface, making it less susceptible to cracking or chipping during the cutting process. This characteristic of spherical ice requires specialized cutting techniques that respect the structural integrity of the sphere, ensuring a smooth and clear finish. In contrast, cutting non-spherical ice as an aspect of embodiments of the invention, such as into cubes or other angular forms, demands a different methodology due to the presence of edges and corners, which are potential weak points where cracks or chips are more likely to initiate. Furthermore, the task of cutting large, soft blocks of cloudy ice into smaller segments is fundamentally distinct from the precision required to cut smaller, transparent cubes. Cloudy ice, often softer due to trapped impurities and air bubbles, can be more forgiving during the cutting process, whereas transparent ice, valued for its purity and clarity, necessitates a meticulous and controlled approach to preserve its aesthetic and structural qualities. Embodiments of the invention, therefore, incorporate a cutting module comprising specific cutting techniques and tools designed to accommodate the nuances of working with transparent ice in various shapes, ensuring that each piece retains its intended clarity and form without the introduction of unwanted flaws.
The preferred embodiment specifies the use of a thermoelectric pad or a refrigeration system that delivers sufficient BTUs to produce transparent ice cubes with a Moh hardness of 2-6. In the preferred embodiment of the present invention, the thermoelectric pad is meticulously engineered to operate at an optimal current of 5 amps, and more preferably at 9 amps, to efficiently produce transparent ice cubes with a Mohs hardness of at least 2, which may increase depending on specific conditions. This enhanced hardness not only ensures the longevity of the ice cube within a beverage but also contributes to the overall quality and presentation. The transparent ice cubes produced in conjunction with a refrigeration pipe system exhibit a Mohs hardness ranging from 2 to 6, a testament to the robustness of the ice produced by the present invention. The refrigeration system itself in the context of embodiments of the invention is designed to deliver substantial cooling power, providing over 1,000 BTUs in embodiments and, in association with the preferred embodiment, in excess of 2,500 BTUs. The present inventor has determined that this level of thermal energy is beneficial for achieving the desired hardness of 2-6 Moh, and the desired clarity of the ice cubes. This configuration serves as an illustrative example and is not intended to limit the scope of the invention. For comparison, brass-a metal known for its relative softness—has a Mohs hardness of 3. Those skilled in the art will appreciate that the hardness of ice varies with temperature: at its melting point, ice exhibits a Mohs hardness of 1.5, but this hardness can increase significantly under colder conditions. For instance, at −44° C. (−47° F.), the hardness of ice approaches 4, and it can reach a hardness of 6 at −78.5° C. (−109.3° F.), which corresponds to the sublimation point of solid carbon dioxide, commonly known as dry ice. Moreover, the hardness of the transparent ice cubes produced in accordance with the invention makes them significantly harder than the average cloudy ice cube. This hardness not only contributes to the longevity of the ice when placed in a drink but also requires a specialized approach to cutting the ice into non-spherical shapes. The present invention addresses this need by employing a cutting mechanism that is tailored to handle the increased hardness without causing damage to the ice cubes, differentiating it from prior art attempts. This results in a final product that is not only visually appealing but also possesses the physical properties necessary for a superior ice cube, capable of withstanding the rigors of handling and use without compromising its integrity.
A configuration of cutting module in an embodiment comprises one or more chromium blades. A chromium blade in the context of the invention is defined as a blade comprising at least 15 percent chromium content. Among other advantages, the present inventor has found that use of a chromium blade minimizes blade wobble, and has therefore found the use of a chromium blade important in association with the preferred embodiment for cutting hard transparent ice cubes without causing damage. The minimization of blade wobble during the cutting process has been found by the present inventor as important for maintaining the integrity of the ice cubes. The chromium blade's rigidity and resistance to flexing allow for precise cuts without causing chips or cracks, making it an important component of the preferred embodiment to facilitate the processing of transparent ice cubes within the critical hardness range of 2-6 Moh. The rigidity of the chromium blade in accordance with the preferred embodiment ensures precision cuts without the deformation that could lead to inaccuracies or damage to the ice cubes. The blade's design allows it to be tightly secured, or ‘sinched down,’ to minimize any lateral movement, commonly referred to as ‘wobble.’ This stability is crucial when cutting small, non-spherical transparent ice cubes, as even minor wobbling could introduce fractures or chips, compromising the cube's structural integrity and aesthetic clarity.
In association with the preferred embodiment, the operational parameters of the blade are finely tuned to optimize the cutting process. The blade's revolutions per minute (rpm) are set to exceed 2,000 rpm but remain below 8,500 rpm, with an ideal operational speed of around 3,500 rpm. This speed range balances the need for efficient cutting with the control necessary to prevent damage to the ice. The cut rate, or the speed at which the ice passes through the blade, ranges from approximately 60 inches to 180 inches per minute, with a preferred rate of about 80 inches per minute. This rate may be adjusted based on the specific conditions of the ice being cut, such as size and hardness. In accordance with the performance of the invention, attention is also given to the blade's teeth count, which affects the smoothness and precision of the cut. The blade in the preferred embodiment features between 2-12 teeth per inch, with an optimal range of 2-6 teeth per inch, and most ideally, 2-4 teeth per inch. The blade width in the preferred embodiment is maintained at about ¼ of an inch or less to ensure clean cuts without excessive material removal that could lead to structural weaknesses in the ice. To further enhance the stability of the blade in its preferred embodiment during high-speed operation, rings are employed on each side of the blade to reduce wobble to less than about 0.03 of an inch, and more preferably, to less than 0.01 of an inch. These rings are critical in maintaining the blade's alignment and preventing the small but significant lateral movements that could otherwise damage the ice. The configurations and methods to reduce or eliminate blade wobbling at high cut rates, are particularly useful in accordance with ensuring that the smaller non-spherical transparent ice cubes, measuring less than 3″×3″×5″ and preferably about 2″'2″'2″, are cut with no visible cracks or chips, further differentiating the present invention from prior art attempts which do not optimally cut smaller pieces of ice without visible cracks or chips.
In some embodiments of the invention, multiple blades are utilized. In configurations where multiple blades are utilized, the spacing between the blades is carefully considered. Adequate spacing is necessary to prevent the ice cubes from vibrating excessively, which could lead to cracking or chipping. However, for spherical ice shapes, blade spacing is less critical as the shape inherently resists such damage.
The quality of the ice itself is also a consideration directly associated with the cutting process in accordance with the invention. In the preferred embodiment, the ice cubes have a calcium carbonate content within the critical range of less than 260 milligrams per liter, with lower concentrations preferred to reduce the risk of cracking or chipping during cutting. The present inventor has likewise discovered that lower calcium carbonate levels also prevent the ice from exhibiting a milky appearance, ensuring the cubes remain crystal clear.
An integral aspect of the preferred embodiment is the stringent adherence to the use of Food Grade or Food Safe materials for all components that come into direct contact with water during the ice-making process. This commitment ensures that the transparent ice cubes produced are not only aesthetically pleasing but also fully compliant with the health and safety standards required for human consumption within the United States. A particular focus is placed on the exclusion of Bisphenol A (BPA) from the composition of the ice cube molds used in the invention. In response to concerns surrounding the use of BPA, in the preferred embodiment, the associated ice cube mold is completely BPA-free, exceeding the FDA's current stance on the safety of BPA. This decision reflects a commitment to consumer health and aligns with a precautionary principle, catering to the growing demand for BPA-free products.
An embodiment of the invention provides a method to prevent visible crystallization within the center of a transparent ice cube. It involves controlling the water movement pressure within a properly configured ice mold to prevent the alignment of water molecules into visible crystals as the water transitions from liquid to solid state. An integral aspect of the preferred embodiment is its approach to preventing visible crystallization within the center of a transparent ice cube, a common issue that detracts from the desired aesthetic quality of the ice. The preferred embodiment addresses the solubility of atmospheric gases, such as nitrogen and oxygen, in water—a factor influenced by the water's temperature and the atmospheric pressure at the air/water interface. Typically, colder water under higher pressure can dissolve more gas, while warmer water under lower pressure dissolves less. In the liquid state, water molecules are in a state of constant motion, but as freezing occurs, these molecules slow down and begin to align in structured formations, leading to crystallization. The preferred embodiment manipulates this process by applying precise water movement pressure within a specially designed ice mold. The water movement pressure is adjusted to ensure that water droplets jump at least ⅛th of an inch above the water's surface, which is a critical parameter for preventing the alignment of water molecules into visible crystalline structures in accordance with the preferred embodiment. This precise control of water movement is facilitated by the use of a refrigeration system that includes a refrigeration pipe or thermoelectric pad, which is held in thermal communication with the ice mold throughout the freezing cycle. This system in accordance with the preferred embodiment is designed to maintain constant thermal communication with the ice mold for the duration of the freezing cycle. Unlike prior art, which does not sufficiently maintain such thermal communication, the preferred embodiment ensures that the refrigeration pipe or thermoelectric pad is not only in proximity to the ice mold but is also mechanically secured to it, thereby guaranteeing efficient heat transfer and uniform ice formation. This precise control of water movement is critical for achieving the high-quality transparency of the ice cubes, as it allows for the consistent and controlled freezing that is essential for preventing the entrapment of air bubbles and impurities. The refrigeration pipe or thermoelectric pad's maintained contact with the ice mold ensures that the temperature is evenly distributed across the entire mold surface, leading to a uniform freezing process that is not addressed by the prior art. This level of control distinguishes the present invention from prior art methods by providing a reliable and repeatable process for producing clear ice cubes, free from the cloudiness and structural weaknesses commonly associated with less controlled freezing techniques.
The ice mold itself is configured to maintain the water under the necessary pressure conditions, ensuring that the freezing process yields ice cubes with the desired clarity and quality. This controlled environment ensures that water molecules do not align excessively during the freezing process, thereby avoiding the formation of visible crystallization. The invention further employs a method where water droplets are induced to jump at least ⅛th of an inch above the water's surface before landing back in the water, promoting substantially one-directional freezing. This technique is critical in forming ice cubes that are visually free from crystals, ensuring the production of clear, high-quality ice with optimal transparency. In an embodiment comprising a refrigeration pipe 119 that further comprises a refrigerant flowing therein and a substantially flat surface 109 comprising a metal bottom wall of a bin 108, wherein the bin 104 comprises four sidewalls, the mold or a related aspect comprises a removable mold insert 110 having only four sidewalls walls and no bottom. The removable mold insert 110 is therefore insertable into the bin 108, the four sidewalls of the mold insert 110 and the metal bottom wall 109 of the bin therefore form a cavity which may be placed into another cavity. In an exemplary embodiment, the cavity that may be placed within another cavity has four sidewalls and a bottom wall comprising a polymer. In an example, the cavity placed within another cavity comprises a metal bottom wall and is removable from the enclosing cavity having a metal bottom wall. In an embodiment, a vibrator 115 or an oscillator vibrates or oscillates the water so water droplets jump at least ⅛th of an inch vertically above a top surface of the water and then back into the water, the refrigeration system is configured with refrigeration fittings such as refrigeration fitting 703 as depicted by
Optimizing the freezing time is crucial for producing high-quality transparent ice cubes. The preferred embodiment comprises specific refrigeration pipe lengths, refrigerant types, and compressor BTUs that, in combination with the cavity configuration, achieve the desired freezing time and ice cube quality. The refrigeration pipes, which are integral to the heat exchange process of the preferred embodiment, are configured with lengths that range from 50 to 160 equivalent feet, depending on the size and capacity of the ice-making system. These pipes are selected to accommodate refrigerants with varying boiling points, including but not limited to, standard low-temperature refrigerants as well as advanced cryogenic options that can reach temperatures as low as −78.5° C. (−109.3° F.), the sublimation point of solid carbon dioxide (dry ice). The compressors employed in the system are chosen for their ability to deliver a substantial cooling effect, with BTU ratings that typically range from 1,000 to over 2,500 BTUs. Examples of compressors suitable for this purpose in association with embodiments of the invention include the Copeland Scroll Compressor, which is known for its reliability and efficiency in delivering the necessary BTUs for optimal freezing. Another example is the Tecumseh Reciprocating Compressor, which offers a range of BTU outputs to match the required refrigeration needs and is compatible with various refrigerant types, including low-temperature and cryogenic options. Additionally, the Danfoss Scroll Compressor could be utilized for its precise control capabilities and high performance, ensuring consistent production of clear ice cubes within the desired freezing time frame. This range of 1,000 to over 2,500 BTUs is critical to ensure that the water freezes at a rate that prevents the formation of visible crystallization and air bubbles in association with the preferred embodiment, resulting in the production of high-quality transparent ice cubes. The compressors are also selected based on their efficiency, with the goal of achieving a freezing time of approximately 4½ to 5½ hours for a standard batch of ice cubes in an ambient temperature of about 75-85 degrees Fahrenheit. This precise calibration of pipe lengths, refrigerant types, and compressor BTUs is essential to the present invention, as it allows for the consistent production of transparent ice cubes with the desired clarity and structural integrity, while also maintaining energy efficiency throughout the freezing process.
The preferred embodiment incorporates a refrigeration system that intentionally vibrates or oscillates the refrigeration piping, a concept that deviates from conventional practices which typically advise against such movement. Traditional concerns regarding the movement of refrigeration piping often stem from the risk of accelerated wear and tear on the components, which can lead to premature failure and refrigerant leakage, issues that have plagued previous attempts in the prior art. To address these concerns and ensure the integrity of the system during the vibration or oscillation cycles, the invention utilizes advanced brazing techniques that incorporate a silver solder with a silver content ranging from 3% to 15%. This specific range of silver content is chosen for its superior strength and ability to create robust, leak-proof joints that can endure the dynamic stresses imposed by the movement. Additionally, the brazing process is enhanced by employing a nitrogen flush, which purges the system of oxygen and other contaminants during the brazing, thereby preventing oxidation and ensuring a clean, strong bond that maintains the hermetic seal of the refrigeration piping. This approach to joining the piping components not only fortifies the system against the potential adverse effects of vibration or oscillation but also contributes to the overall durability and longevity of the refrigeration system, making it a key feature of the invention's design.
The preferred embodiment aims to produce large transparent ice cubes with high energy efficiency, achieving at least 1 pound of ice per 0.245 kilowatt hours of refrigeration energy. The embodiment includes specific refrigeration pipe dimensions, expansion valve sizes, cavity wall thicknesses, and water calcium carbonate content to accomplish this goal. To achieve this goal, the preferred embodiment is equipped with approximately 66 equivalent feet of ½ inch diameter refrigerant pipe, which is integral to the efficient transfer of thermal energy. An expansion valve with a ¼ inch diameter liquid line is selected to regulate the flow of refrigerant precisely, ensuring optimal performance of the system. The cavities, where the ice formation occurs following the introduction and subjugation of introduced water to a freezing cycle facilitated by the refrigeration system, are constructed from a polymer material chosen for its thermal properties, with the cavity walls calibrated to a thickness of less than 0.070 inch. This precise thickness limitation, critical in association with the preferred embodiment, allows for the water within the cavities to freeze thoroughly, transforming it into the desired transparent ice. In association with the refrigeration pipe and cavity design, the system employs a ½ horsepower compressor that is capable of delivering approximately 2500 BTUs in the preferred embodiment. providing the necessary power to drive the freezing process while maintaining energy efficiency. In accordance with the preferred embodiment, the quality of water used is also a key factor in the production of clear ice; therefore, the water introduced into the system a calcium carbonate content of less than 260 milligrams per liter, minimizing the potential for cloudiness and impurities within the ice.
When combined with a refrigeration pipe that maintains thermal communication with the cavity throughout the freezing cycle in accordance with the preferred embodiment, the result is an ice cube that not only extends over 1¼ inch from the cavity wall but also possesses a Mohs hardness exceeding 2. This hardness level has been found by the present inventor as indicative of the ice's durability and longevity when used in various applications.
The present invention is not limited to the aforementioned embodiment; it encompasses all conceivable variations that fall within the scope of the invention. This includes, but is not limited to, alternative refrigeration pipe lengths, diameters, expansion valve sizes, cavity wall materials, and thicknesses, as well as variations in water quality, all of which are contemplated to achieve the same high standard of transparent ice cube production with energy efficiency at its core.
In accordance with the preferred embodiment of the present invention, a novel evaporator design is introduced, featuring a substantially flat freezing surface that is instrumental in distributing the correct amplitude of vibrations to the water within each ice mold. This design is particularly suited for the inherently moist conditions of ice cube production. The innovation lies in the use of metal for the evaporator, which, due to its elastic properties, is highly effective at transmitting vibrations. In contrast, plastic materials, which are viscoelastic, significantly dampen the transmission of vibrations. This distinction is critical in accordance with the preferred embodiment as it directly influences the efficiency and uniformity of ice formation within the molds. The preferred embodiment employs vibrational analysis techniques, utilizing Green's Functions to optimize the vibrational characteristics of the system. As will be appreciated by those skilled in the art, Green's Functions are mathematical constructs used to solve inhomogeneous differential equations that arise in the study of vibrational dynamics, particularly within the context of the present invention's evaporator design. These functions provide a way to describe the response of a system to a point source of force or disturbance, such as the vibrations transmitted through the evaporator plate. By employing Green's Functions, the invention is able to predict and control the behavior of the system under the influence of vibrations, ensuring that the amplitude and frequency are optimized for the formation of clear ice cubes. These functions are employed to calculate the precise frequencies and orthogonality relations for the combined dynamical systems, which include the evaporator plate and the water within the molds. By accounting for the effects of transverse shear and rotary inertia, the preferred embodiment ensures that the amplitude of vibrations is precisely controlled, leading to the desired outcome of clear, uniform ice cubes. The thickness of the metal plate is a key factor in this process in accordance with the preferred embodiment. The present inventor has determined that the optimal thickness range for the metal evaporator plate is between one sixtieth of an inch and three eighths of an inch. This range is not arbitrary but is the result of rigorous testing and analysis to ensure that the amplitude of vibrations is neither too weak to release trapped air from the water nor too strong to cause undesirable turbulence in accordance with the preferred embodiment. Additionally, the size of the freezing surface is designed to match or exceed the footprint of the ice mold, ensuring that the entire mold is subjected to an even distribution of vibrations. For instance, if the ice mold measures ten inches by ten inches, the freezing surface will be at least of the same dimensions, if not larger. This approach to controlling the vibrational environment within the ice molds represents a critical distinctive innovation in accordance with the preferred embodiment. The present inventor has discovered that the unique use of Green's Functions to derive the optimal metal thickness for an evaporator plate, and the specific relationship between the plate thickness and the amplitude of vibrations necessary for producing clear ice cubes. The preferred embodiment's method of applying vibrational analysis to the design of the evaporator plate provides a technical solution that is critical for achieving the desired quality of ice cube production. The incorporation of vibrational dynamics in the context of ice cube manufacturing associated with the preferred embodiment provides substantial improvement over existing technologies.
The preferred embodiment also contemplates an automatic transparent ice machine capable of making and dispensing transparent ice cubes with a Moh hardness of 2-6 and specific dimensions without dimpling. In accordance with the preferred embodiment, the machine is configured create ice cubes that not only possess the desired clarity but also exhibit specific dimensions, ensuring uniformity in size without the occurrence of dimpling, which is a common flaw in less precisely controlled freezing processes. The ability to achieve such a range of hardness in transparent ice cubes is important in association with the preferred embodiment, as it requires precise control over the freezing parameters. The preferred embodiment's capability to consistently produce ice cubes without dimpling indicates a level of control over the ice formation process that surpasses the conventional technology, where such imperfections are more prevalent.
The preferred embodiment introduces a user-friendly feature that significantly enhances the versatility of the transparent ice machine. It is designed to allow users to efficiently switch out ice molds, thereby enabling the production of transparent ice cubes in a myriad of shapes and sizes. This aspect of the preferred embodiment eliminates the need for tools or the disassembly of any part of the ice maker, which is a marked departure from conventional automatic ice makers that typically require manufacturer intervention for mold changes. The ice molds are designed in accordance with the preferred embodiment to be easily removable from the transparent ice machine without the necessity of detaching any component of the water movement system, which is often integrated within the freezer compartment of a refrigerator.
This embodiment of the invention not only simplifies the mold exchange process but also addresses a common issue found in other ice-making methods—ice cubes sticking together post-production. By facilitating the removal of only the ice mold, this aspect minimizes the likelihood of ice cubes fusing together during packaging or storage, ensuring that the cubes remain separate and intact. The flexibility offered by this design is not limited to the examples provided but extends to encompass all conceivable methods that could reduce or ideally eliminate the rejoining of ice cubes once they have been packaged. This aspect thus provides a practical solution that significantly improves the user experience and the functionality of the ice-making process in association with the preferred embodiment.
In accordance with the preferred embodiment, a critical aspect is the integration of an evaporator or freezing surface that is exceptionally resistant to corrosion, exhibiting a penetration rate of less than five mils per year. This durability is critical in environments where the freezing surface is exposed to conditions that could potentially degrade its quality over time. Moreover, the freezing surface is engineered to possess a thermal conductivity exceeding fourteen watts per meter-Kelvin, ensuring efficient heat transfer during the ice-making process. A crucial function of the freezing surface in accordance with the preferred embodiment is its ability to provide proper attenuation, which is essential for the precise distribution of specific frequencies and amplitudes across multiple ice molds. This distribution is vital for the consistent production of high-quality transparent ice cubes in accordance with the preferred embodiment. To illustrate the versatility of materials that can achieve these objectives, ceramic is presented as an exemplary material used in one embodiment of the invention. The choice of ceramic demonstrates an exemplary utilization of materials that offer superior corrosion resistance and thermal properties, although it is understood that the scope of the invention encompasses all materials that meet these criteria. The methodology for determining the corrosion rate involves a calculation that assumes uniform corrosion across the entire surface of the test sample, or coupon. The formula used to calculate the mils per year penetration rate (mpy) is as follows: mpy=(weight loss in grams)*(22,300)/(Adt), where ‘A’ represents the area of the coupon in square inches, ‘d’ is the density of the coupon's material in grams per cubic centimeter, and ‘t’ is the duration of exposure to the corrosive environment in days. This formula as will be appreciated by those skilled in the art is a standard in the industry for assessing the longevity and performance of materials used in corrosive environments, and it serves as a benchmark for the materials selected for use in the preferred embodiment's freezing surfaces. The preferred embodiment details the appropriate sizing of the refrigeration system, including piping and compressor, to deliver the required BTUs. It also encompasses an ice mold lid designed to compensate for opposing BTUs during the freezing process, ensuring even freezing of the water in the molds.
A distinctive aspect of the preferred embodiment is an ice tray that serves a dual purpose: it not only forms the ice cubes but also functions as the final packaging for the end user. This dual functionality streamlines the process by removing the need for additional repackaging, which is a standard practice in the bulk ice cube industry. This approach not only reduces packaging costs but also addresses a common issue in ice cube distribution-ice cubes sticking together after packaging. In accordance with the preferred embodiment, the present inventor has recognized that when larger ice cubes are sectioned into smaller sizes, these smaller ice cubes are then placed into a specially designed package. This package features individual cavities tailored to each ice cube, effectively preventing the cubes from fusing back together during transport or storage. This aspect materially differs from known prior art that offers transparent ice cubes sold directly in the manufacturing tray, and therefore represents a significant departure from traditional practices.
An additional aspect pertains to the refrigeration system's configuration, specifically the sizing of its components, which in accordance with the preferred embodiment is critical for optimal performance. The preferred embodiment incorporates a refrigeration system that is meticulously calibrated in terms of the dimensions and capacities of its piping and compressor to ensure efficient operation. In accordance with an embodiment, the refrigeration system includes a suction line segment of the refrigeration pipe that is notably sized between one-half and one inch in diameter. This segment extends over 25 feet in length and is capable of delivering approximately 1000 British Thermal Units (BTUs). Complementing this, the system features a liquid line segment with a diameter of about one-quarter of an inch or less, which is particularly significant given that standard refrigeration piping charts recommend a liquid piping line diameter of three-eighths of an inch for systems providing over 1000 BTUs with equivalent lengths of 25 feet or more for pipes with a diameter of one-half inch or larger. This tailored design in accordance with the preferred embodiment, as depicted in
In accordance with embodiments of the invention, an ice mold lid ingeniously designed to balance the thermal dynamics involved in the ice-making process is provided. This lid is precisely calibrated to counteract the British Thermal Units (BTUs) emitted by the refrigeration system's piping situated beneath the ice molds. The calibration ensures that the lid permits the passage of warm room temperature air, specifically calibrated to a temperature such as seventy degrees Fahrenheit, to neutralize the cooling effect of the BTUs from the refrigeration pipe. This design prevents the premature freezing of the water's top surface, thereby allowing a uniform freezing process throughout the entire volume of water contained within the molds. For instance, in an exemplary embodiment, the refrigeration system is rated to deliver twenty-four hundred BTUs, and the lid is engineered with a thickness of less than 0.016 inches to achieve the desired thermal compensation. It is important to note that in various embodiments the invention encompasses a broad range of lid configurations that effectively adjust for the BTU output of the underlying refrigeration system. This distinguishing aspect in contrast to prior art attempts ensures that all the water within the ice molds transitions to ice in a controlled and efficient manner.
The aforementioned aspects of the invention, along with the detailed descriptions provided, demonstrate the novel and non-obvious nature of the disclosed embodiments, and evidence significant advancements over the prior art in the field of ice cube production. Turning now more specifically to the figures, various aspects of the invention are more particularly presented.
If the refrigeration pipe were not in thermal communication throughout a vibration or oscillation cycle an air space between the cavity and the pipe would not allow the ice cube to extend over 1¼ of an inch from a wall of the cavity using one directional freezing of the water in the cavity. Even if the air under the cavity were extremely cold to initially freeze the water, the water in the cavity would warm the air right under the cavity to the degree the ice cube would never extend over 1¼ inch from a wall of the cavity. In one embodiment the bottom wall is metal and provides the ice cube extends over 1¼ inch from a wall of the cavity.
In one embodiment, the thermal conductivity of plate 109 is over 15 watts per meter-Kelvin and more preferably over forty watts per meter-Kelvin. In one embodiment refrigeration pipe 2702 has a diameter of ⅝ inch and a length of about between 130-160 equivalent feet and more preferably about 150 equivalent feet. In one embodiment refrigeration pipe 102 has a diameter of 1/2 inch and is about 62 feet in equivalent feet long. In one embodiment all molds or cavities hold about 48 pounds of water and the refrigeration compressor 2721 uses in one embodiment about 36 kilowatt hours of refrigeration energy within a 24 hour period. In one embodiment refrigeration compressor 2712 or another refrigeration compressor is configured with other components (not shown) to cool a gas temperature so it is less than 60 degrees Fahrenheit and more preferably less than about 45 degree Fahrenheit and higher than 32 degrees F. If the gas has a lower temperature the top surface of the water may require heating. In one embodiment the gas is injected into the water of a cavity herein. One of ordinary skill in the art would know how to configure refrigeration compressor 2721 with other components to accomplish this goal from reading this disclosure. In one In one embodiment ice maker is configured to make over 49 pounds of ice per day and provides 4, or 5, or 6 or more cycles within a 24 hour period freezing 48 pounds of ice per cycle. In one embodiment ice maker 2700A produces 100 pounds of transparent ice using less than about 24.5, 19, 15, 12, or 10 or less kilowatt hours of energy. The water is frozen outwards from a wall 2709 of the cavities 2710 and extends 1¼ inch, 1½ inch or about 2 inches or more from the wall. One embodiment of the Present Invention allows a small amount of oil to circulate in the refrigeration pipe 102. In one embodiment of the Present Invention compressor assembly 100 has either a one half horsepower or three quarters horsepower motor with less than one inch outside diameter piping and the piping 102 has a length of between 50 and 100 equivalent feet to provide the proper movement of oil within the refrigeration piping and deliver the proper refrigeration to make quality transparent ice cubes. In one embodiment of the Present Invention refrigeration pipe 102 has a segment located between bin 108 and compressor assembly 100 is insulated with a water resistant insulation having a thickness over about one quarter inch thick. Expansion valve 103 is either an automatic expansion valve, a thermostatic expansion valve, a float valve, low side float valve, high side float valve, a capillary tube or an electronic expansion valve or another type. In one embodiment of the Present Invention there are at least two or more expansion valve 103. In one embodiment of the Present Invention there are at least two or more expansion valve 103 where one is located above the other. From reading this disclosure one of ordinary skill in the art would know how to accomplish this goal. In one embodiment of the Present Invention there are at least one expansion valve 103 for each bin 108 where the bin 108 measures more than twenty four inches by more than twenty four inches. One embodiment of the Present Invention has multiple bins with an expansion valve 103 for each bin 108. In one embodiment of the Present Invention there are two bin 108 side by side. One of ordinary skill in the art would know how to accomplish is goal from this disclosure. In one embodiment of the Present Invention water is frozen in bin cavity 108 from the bottom of the bin to the top of the bin. This embodiment eliminates an ice mold. In one embodiment of the Present Invention bin 108 is configured to hold water without leaking. In one embodiment this eliminates the need for a removable ice mold 111. Further this configuration provides for an ice cube (not shown) to have a substantially smooth and level sidewall before cutting the ice cube as the sidewall of bin 108 in one embodiment of the Present Invention is substantially smooth and level. One way this can be accomplished is forming bin 108 in one piece or sealing all seams and openings in bin 108. The configuration of bin 108 to hold water is by way of example and not limitation as the Present Invention envisions all ways for bin 108 to hold water and all ways fall into the scope of the Present Invention. This embodiment eliminates the need for a separate ice mold 111. In one embodiment having multiple bin 108's, each bin 108 has an expansion valve 103. In one embodiment bin 108 is configured to be watertight. In one embodiment bin 108 is positioned upside down so water is released upwards into bin 108 in a continuous flow. Bottom walls disclosed herein can also be top walls when the bins or molds are inverted. One way to reduce the temperature of a refrigerant inside the refrigeration pipe is to turn off the system. In one embodiment substantially flat surface plate 109 forms the substantially flat surface bottom wall of a cavity here such as found in
A key feature of an embodiment is the substantially flat surface plate, item 109, which, with the assistance of a refrigeration pipe or thermoelectric plate, extracts heat from water contained within a cavity or mold. This surface plate 109 is designed to remain stable without substantial tilting from side to side or back and forth during the ice cube formation process. A second cavity, made of food-grade material and comprising five walls constructed from an amorphous solid polymer material with a thermal conductivity of less than 2 watts per meter-Kelvin, is designed to interface with the substantially flat surface plate 109. The thickness of the amorphous solid material is such that it enables the freezing of water through the material to form an ice cube that extends or freezes over 1¼ inch outward from the bottom wall of the second cavity. This embodiment of the ice machine is further configured to freeze a portion of the water with an energy efficiency of at least 1 pound of ice cubes per 0.245 kilowatt hours of refrigeration system energy. The thickness of the polymer in one embodiment is 0.070 of an inch. The substantially flat surface bottom wall of a cavity herein is made from a polymer with a thermal conductivity of less than 0.60 watts per meter-Kelvin, which facilitates the freezing of water through the polymer. Thus, a combination of the segment of the refrigeration system (refrigeration pipe with refrigerant flowing therein) and the cavity ensures that the ice cube extends over 1¼ inch from a wall of the cavity. If the refrigeration pipe were not in thermal communication throughout a vibration or oscillation cycle, an air space between the cavity and the pipe would prevent the ice cube from extending over 1¼ inch from a wall of the cavity using one-directional freezing of the water in the cavity. Even if the air under the cavity were extremely cold initially to freeze the water, the water in the cavity would warm the air right under the cavity to the degree that the ice cube would never extend over 1¼ inch from a wall of the cavity. In one embodiment, the bottom wall is metal and provides that the ice cube extends over 1¼ inch from a wall of the cavity.
In one embodiment of the present invention the entire bid 108 has a metal surface and the metal has a corrosive penetration rate of less than five mils per year. One embodiment of the Present Invention has a suction line segment of refrigeration pipe 102 having a diameter of a between one half and inch and one inch and has an equivalent length of over 25 feet and provides about 1000 BTUs. A liquid line segment 1107 in
Cart 105 has vibration adjusters 107 (also known as vibration isolators or vibration dampeners), is shown in one embodiment of the Present Invention between cart 105 and bin 108. Vibration adjusters 107 are attached to any segment of transparent ice cube maker 101 including various places on mold 111 and number between one, two, three, four or more. Vibration isolators are important as they reduce the chance the joints of the copper pipe leak from continual vibration. Vibration adjustors 107 are shown by way of example and not limitation. The Present Invention contemplates all configurations of vibration adjustors 107 and all configurations and materials fall into the scope of the Present Invention. In one embodiment of the present invention, expansion valve 103 is configured with compressor 100 to provide a superheat of between ten and fifty-degrees Fahrenheit and most preferably about thirty-five degrees Fahrenheit. In one embodiment of the Present Invention, the height of ice mold 111 is such that when an amplitude is subjected to water therein (not shown), water does not splash outside mold 111. In one embodiment of the Present Invention, vibrator 115 is attached to cover 114 and cover 114 goes over bin 108 and in one embodiment is configured to vibrate mold 111. In one embodiment the cover 114 has a metal surface and inside (not shown) is insulation that in one embodiment has a thermal resistance (R-Valve) of about five and more preferably over ten. In one embodiment cover 114 has a surface made out of metal and insulation. In one embodiment there are two or more bin 108 and one bin is positioned over the other bin. Therefore bin 108 and cover 114 or access to provide an enclosed space ice mold 111 or for a cavity within this disclosure and refrigeration piping or thermoelectric pad shown herein. In one embodiment the enclosure is configured to help control the environment so that when a cryogenic compressor or cryogenic pump is used with super cold temperatures the environment is kept so its temperature differentiation from the ice cube is not enough to crack the ice cube from thermal shock. In one embodiment cover 114 is hinged to bin 108 (cavity) and opens from the top. Opening from the top is important because it reduces the environment space within bin 108 enclosure and that results in energy efficiency over a side opening so you can make a transparent ice cube in a reasonable amount of time. This is especially true for thermoelectric embodiment of the present invention. Each cavity herein is configured to provide substantially one directional freezing. As an example and not limitation sidewalls of a cavity have a thickness or a heat conductivity or insulated such that water therein cannot be frozen through the sidewalls and only frozen through the bottom wall. One of ordinary skill in the art would know how to accomplish this goal from reading this disclosure. The present invention contemplates all ways to provide substantially one directional freezing and all ways fall into the scope of the present invention.
In one embodiment of the Present Invention, cover 114 or access door is heated to heat the top surface of water (not 20 shown) in mold 111. In one embodiment, mold 111 is made from a plastic that is free from bisphenol A. In one embodiment of the Present Invention, vibrator 115 is located under freezing surface 109 and freezing surface 109 is made from corrosive resistant material. In one embodiment of the present invention, cavities 112 are made from either a thermoplastic polymer or an inorganic polymer or a fibrous material. One embodiment of the Present Invention provides that cavities 112 are flexible. In one embodiment flexing is important for ease of releasing the ice (not shown) from the cavities 112. Cavities 112 can be one large cavity as a standalone mold or multiple cavities as shown. In one embodiment of the Present Invention, mold insert 110 sits atop freezing surface 109 creating a cavity. In one embodiment the bottom wall of cavities 112 are metal having a thermal conductivity over 14 watts per meter-Kelvin and in one embodiment they are made from polymer, and Mold receiver 110 provides insulation to the cavities 112 as cavities 112 insert into insert 110 so that when water (not shown) is put in the cavities 112 the cavities 112 touch a segment of the mold receiver 110 sidewalls 113. Mold receiver insert 110 has cavities the cavities 112 slip into. The mold receiver thus provides one directional freezing of water. The mold receiver 110 is shown by way of example and not limitation as the Present Invention contemplates all ways to provide one directional freezing of water and all ways fall into the scope of the Present Invention. In one embodiment a segment refrigeration pipe 102 is insulated. In one embodiment of the Present Invention insulated cover 114 has a segment that is made in part of out of foam insulation board or a material having a thermal conductivity less than ten watts per meter-Kelvin. In one embodiment of the Present Invention the insulation board measures over one and one half inch thick. In one embodiment of the present invention mold 111 is untreated without a wax or other coating. In one embodiment of the present invention cover 114 is made out of plexiglass, see through plastic, plastic, metal 5 or another material. In one embodiment a sidewall of cavities 112 will flex or bow out when filled with water while it is outside bin 108. In one embodiment mold receiver 110 provides insulation between two sidewalls of cavities 112. The present invention contemplates all ways to attach cover or door 114 to bin 108 and all ways fall into the scope of the present invention.
Within the scope of the preferred embodiment, an aspect of the invention is characterized by the incorporation of a vibration mechanism, denoted as vibrator 115, which is securely affixed to a rigid metal plate, referred to as plate 115B. This assembly is connected to the transparent ice maker, identified as item 101, through a variety of attachment methods that are designed to ensure stability and durability during operation. An aspect of this embodiment is the inclusion of a control knob, labeled as 115A, which grants the user the capability to finely adjust both the frequency and amplitude of the vibrations. This level of control directly influences the agitation process of the water within the ice maker, which is a key factor in achieving the desired quality of the transparent ice cubes. The ability to adjust amplitude is of importance in accordance with the preferred embodiment, as unlike previous attempts in the prior art, which do not provide the requisite amplitude necessary to prevent the entrapment of visible bubbles within the ice, the preferred embodiment provides a means to achieve an amplitude that ensures water droplets jump at least ⅛th of an inch above the water surface and then return, thereby mitigating the formation of visible bubbles in the resulting ice cubes. This feature is critical in accordance with the preferred embodiment for producing transparent ice cubes that are devoid of visible crystallization and clear bubbles, which is not achievable by conventionally known devices.
Referenced in
Member plate 119A is located under refrigeration pipe 119 and therefore refrigeration pipe 119 in one embodiment located between member 119A and freezing surface 109 keeping refrigeration pipe 119 in thermal communication with freezing surface 109. Vibrator 115 is shown under member 119A which in one embodiment of the Preferred embodiment vibrates refrigeration pipe 119, a refrigerant (not shown) inside refrigeration pipe 119 and surface 109 simultaneously. Member plate 119A is either made of metal having a corrosive penetration rate of less than five mils per year or made from foam insulation board measuring about one inch thick to about two inches thick. Member plate 119A is shown by way of example and not limitation as member plate 119A has numerous shapes and sizes and all shapes and sizes fall into the scope of the preferred embodiment. In an embodiment a refrigeration pipe 119 having a refrigerant flowing therein, the substantially flat surface 109 is a metal bottom wall of a bin 108 and the bin has four sidewalls, a removable mold insert 110 having only four sidewalls walls and no bottom wall is inserted into the bin 108, the four sidewalls of the mold insert 110 and the metal bottom wall 109 of the bin form a cavity and cavity 112 has four sidewalls and a bottom wall that are made of a polymer, the cavity 112 inserts into and is enclosed by the created enclosing cavity having a metal bottom wall and the cavity 112 is removable from the enclosing cavity having a metal bottom wall. In an embodiment, a vibrator 115 or an oscillator shown herein vibrates or oscillates the water so water droplets jump at least ⅛th of an inch vertically above a top surface of the water and then back into the water, and the refrigeration system is configured with refrigeration such as refrigeration fitting 703 depicted by
In one embodiment, refrigeration pipe 119 has a heater 120A to heat a refrigerant (not shown) in refrigeration pipe 119. In one embodiment, liquid refrigeration line 119D has a warm liquid or warm gas inside (not shown) so when refrigeration line 119D is placed in close proximity to refrigeration pipe 119 it heats a cold refrigerant (not shown) inside refrigeration pipe 119 to the degree it does not flow back to and freeze compressor 100 in
In one embodiment of the present invention, ice tray 200 is configured to mold receiver 110 in
In one embodiment of the present invention, vibrator 115 is attached to ice tray 200. Label 208 has the name (not shown) of the entity that makes the transparent ice cubes (not shown). In a novel approach the ice cubes (not shown) made in tray 200 are sold in the same ice tray 200 to the end user. The present inventor has recognized that most commercial producers of ice cubes remove the ice cubes from an ice maker and repackage them, and therefore an embodiment facilitates such process. In one embodiment of the present invention, a non-alcoholic flavor 209 is provided to water 204.
In one embodiment of the present invention, handle 211 is attached to transparent ice treat 212. The handle 211 in accordance with various embodiments is made of a variety of material in a variety of configurations and most preferably made from a transparent material. In one embodiment of the present invention, handle 211 is placed in opening 210 so when water 204 phase-transforms, handle 211 attaches to the ice treat 212. The attachment of the handle is 10 an illustration and not limitation and there are various ways to attach. One of ordinary skill in the art knows how to attach a handle 211 to ice treat 212. In one embodiment of the present invention, sidewalls 206 are configured to have a thickness of plastic to provide heat conductivity of less than 0.55 watts per meter-Kelvin (W/mK). In one embodiment of the present invention, opening 210 allows heat to go through lid 201. Opening 210 is small enough to reduce the chance of a droplet from jumping outside cavities 205. In one embodiment bottom wall BB is configured not to tilt back and forth or from side to side when water 204 is starting to freeze. In one embodiment sidewalls 206 and bottom wall 207 are made from an amorphous solid material having a thermal conductivity of less than about 2 watts per meter-Kelvin and a thickness less than 0.070 inches.
It is an aspect of the invention to provided has or air in one embodiment within a segment off the refrigeration system. In one embodiment of the present invention, metal substantially flat surface plate 301 goes between substantially flat surface bottom wall 207 and fan 300 and bottom wall 207 contacts metal plate 301. Fan 300 wicks away gas under cavities 205 that has been warmed by water 204 in cavities 205 keeping colder gas in thermal communication with substantially flat surface plate 301 or bottom wall 207 or cavities 205 or just one cavity. In one embodiment fan 300 has batteries or operated on a direct current or alternating current. In one embodiment of the present invention, fan 300 is configured to provide different fan speeds. In one embodiment of the present invention, ice tray 200 is configured to be crushable or compressible or flexible using one quarter pound per square inch of pressure or placing a one-pound weight on the bottom wall of tray 200. In one embodiment of the present invention, sidewalls 206 are thicker than bottom wall 207. In one embodiment, sidewalls 206 flex when water is added. The Present invention contemplates all configurations and materials of ice tray 200 (cavity) and all configurations and materials of ice tray 200 fall into the scope of the present invention. The fan location and configuration is shown by way of example and not limitation as the present invention contemplates various locations for the fan and all locations and configurations of the fan fall into the scope of the present invention. The cavities have five walls and four of the walls have a thermal conductivity of less than 2 watts per meter-Kelvin and do not have a well-organized crystalline lattice structure and one of the walls is made from a material having a well-organized crystalline lattice structure and a thermal conductivity over 14 watts per meter-Kelvin and a thickness less than ⅜ths of an inch and more preferably about ⅛″ to ¼″, the five walls are put together to form a seal and in one embodiment a watertight seal. In one embodiment the sidewalls and bottom wall is made from two dissimilar materials. A second cavity (not shown is configured having five walls made out of an amorphous solid polymer material having a thermal conductivity of less than 2 watts per meter-Kelvin inserts into cavity 200 so a bottom wall of the second cavity touches the substantially flat surface metal bottom of cavity, and the thickness of solid material is less than 0.070 inches to allow heat to be drawn water from the water to form an ice cube that extends over 1½ inch to 2½ inch from a substantially flat bottom wall of a cavity shown herein. In one embodiment a refrigeration pipe herein having a refrigerant flowing therein is in thermal communication with a cavity herein that has a bottom wall including a polymer having a thermal conductivity of less than 0.60 watts per meter-Kelvin and the bottom wall and the refrigeration pipe are configured together so the water freezes through the polymer and provides that the ice cube extends the over 1¼ inch from the wall of the cavity, and a segment of the ice cube has a Moh hardness of at least 2.
As depicted in
Illustrated in
This freezing cycle duration is critical in accordance with the preferred embodiment; a shorter cycle would not yield a large cube, while an extended cycle would result in complete freezing of the water. The presence of a water layer atop the ice cube during the freezing process is an aspect of this embodiment, particularly for ice cubes measuring less than 3 inches in each dimension, where the water layer must be at least ⅛th of an inch deep, and for larger cubes, at least 1 inch deep. This water layer is subsequently removed before the ice cube is extracted from the cavity, ensuring the integrity of the cube's structure.
Various embodiments encompass a comprehensive range of methods to maintain the refrigeration pipe or thermoelectric pad in both thermal and mechanical communication with a substantially flat surface throughout the entire freezing process, as well as during any vibration or oscillation cycles. This ensures the effective transfer of heat from the water within a cavity or mold to the refrigeration system, which is critical for the formation of high-quality ice. The scope of the invention includes, but is not limited to, the use of various attachment techniques such as welding, chemical bonding, clipping, screwing, bolting, and the use of nuts, as well as the incorporation of plate wall members and insulation wall members. A key aspect of the preferred embodiment is the design of the substantially flat surface, which is engineered to remain stable without substantial tilting from side to side or back and forth. This stability is crucial for the consistent performance of the refrigeration system and the quality of the ice produced. The substantially flat surface, aided by a refrigeration pipe or thermoelectric pad, effectively draws heat from the water contained within a cavity or mold, as depicted within this disclosure.
All components of the molds, inserts, cavities, and bins described herein are designed to be compatible with the thermoelectric pads, allowing for various configurations and embodiments within the scope of the invention. For instance, a cavity, mold, or insert component may be constructed entirely from a compression-molded elastomer material that is resistant to animal fats, chemicals, and water in an embodiment. This material choice not only contributes to the efficient unidirectional freezing of water within a cavity but also facilitates the subsequent removal of the ice cube.
In accordance with the preferred embodiment, a vibrator or oscillator is employed to agitate the water in such a manner that water droplets are propelled at least ⅛th of an inch above the water's surface before returning to the cavity. This agitation technique is essential in accordance with the preferred embodiment for preventing the entrapment of air bubbles within the ice, which would otherwise compromise the clarity and quality of the final ice product.
As illustrated in
As depicted by
Arm 1712 is shown by way of example and not limitation as the present invention contemplates all ways to feed ice cube 1713 into blades 2301 and all ways fall into the scope of the present invention. The feed rate, blade tooth count of 2-6 teeth per inch and the revelations per minute of the blades cuts an ice cube into smaller ice cubes without visible cracks or visible chips in the smaller ice cubes. Transparent ice is generally much harder than non-transparent ice cubes and therefore some embodiment of the transparent ice herein requires a configuration of blades and feed rates to cut them. In one embodiment smaller ice cubes 1710 measure over 1¼″×1¼″×1¼″ and less than 3″×3″×5″ and more preferably less than 2½″×2½″×2½″ that have no visible cracks and no visible chips.
In
Ice cube 2008 is shown by way of example and not limitation. Ice cube is 2008 configured having a center portion from 30 percent to 100 percent of the ice cube 2008, that lacks visible bubbles, visible crystallization, visible cracks, visible chips and lacks a milky appearance. When a thermoelectric pad is used it can take 8-12 hours to make 4-8 transparent ice cubes. A top opening lid is preferable because this configuration allows less space between the surface of water 2003 and the lid 2010 or 2004A that is also in one moment configured as a lid. The less space the better for freezing efficiencies. In one embodiment by way of example and not limitation stem 2004 has a paddle configuration and the paddle is half the size of a bottom wall of a cavity it goes into and the paddles spin at about 30 times per minute and this together with other components of the preferred embodiment configure an ice cube 2008 so it lacks visible crystallization and lacks visible bubbles. If the stem 2004 had a small diameter, it would require a much higher RPM to eliminate visible crystallization but that high rate would create visible bubbles that would be visibly trapped in the ice cube. With the example shown persons of ordinary skill in the art would be able to adjust the RPMs for a different configuration of stem 2004 and/or cavity 2016. The present invention contemplates all configurations of stem 2004 and cavity 2016 capable of achieving the goal of eliminating visible crystallization and visible bubbles. Therefore, each embodiment of the stem 2004 may have a customize configuration and the configuration is calibrated to a size of the cavity 2016 and a spin rate of stem 2004 in each embodiment may be configured to the stem 2004 configuration and the size of the cavity 2016 to provide that the ice cube 2008 lacks the visible crystallization and lacks the visible bubbles. In one embodiment the stem 2004 spins in one direction and then spins in reverse and repeats this back and forth action to agitation water in a cavity 2016. Therefore, the configuration of the stem 2004 in relationship to the size of the cavity 2016 and the spin rate is critical to make the preferred embodiment for this embodiment. In various embodiments, stem 2004 is configured to spin the water. In an embodiment, a bottom wall of the cavity 2016 includes a polymer and is configured to have a thermal conductivity of less than 0.60 watts per meter-Kelvin so the water freezes through the polymer. In such embodiment, stem 2004 is configured so a segment of the stem 2004 is submerged in the water during the freezing cycle, the stem 2004 is configured so it spins to move the water in the cavity 2016, and a layer of water at least ⅛th of an inch deep remains on top of the ice cube during the freezing cycle, and after the freezing cycle the layer of water is removed from the top of the ice cube 2008 before the ice cube 2008 is removed from the cavity 2016. The stem 2004 in an embodiment is further configured so it is removable from the water only after the freezing cycle, and the system in an embodiment is configured to produce an ice cube 2008 that measures less than 3 inches by less than 3 inches by less than 3 inches. The configuration to retain at least ⅛th inch deep layer of water on top of the ice cube 2008 is critical to this embodiment. In one embodiment the system is configured such that stem 2004 is configured to move up and down, optionally in coordinative contact with the lid 2010 and opening, and the up and down motion moves or agitates the water so the ice cube lacks visible crystallization and lacks visible bubbles. In one embodiment an ice cube made with stem 2004 has 6 sides.
In accordance with an embodiment, a novel approach to ice cube formation is provided, wherein each cavity within a series of cavities is strategically separated by a space containing gas at a temperature of less than 50 degrees Fahrenheit. This specific temperature-controlled environment is instrumental in mitigating the occurrence of dimpling on the surface of the resulting ice cubes.
In a particular embodiment, the release opening is ingeniously positioned to face a sidewall of the cavity. This orientation ensures that as water is released upward, it first contacts the sidewall, thereby cushioning the impact before the water reaches the bottom wall of the cavity. This method is pivotal in reducing the visible dimpling effect on the ice cube, representing a non-obvious solution to a common problem in ice production. Further, the embodiment describes a cavity configuration where the separation between adjacent cavities is defined by the wall thickness of a second cavity, effectively eliminating any air space between them. These walls are constructed from a food-safe, amorphous solid material with a thermal conductivity of less than 2 watts per meter-Kelvin, ensuring both safety and efficiency. The cavities themselves are composed of five walls, where four exhibit low thermal conductivity, lacking a well-organized crystalline lattice structure. In contrast, one of the walls is a substantially flat surface crafted from a material with a well-organized crystalline lattice structure and a thermal conductivity exceeding 14 watts per meter-Kelvin. This design facilitates efficient heat transfer while maintaining the structural integrity of the ice cube. Incorporated into this embodiment is a cryogenic compressor, item 2712, which is designed to automatically shut down prior to the ice cube reaching temperatures low enough to induce thermal shock and potential cracking. This preemptive measure ensures the preservation of the ice cube's quality and is within the understanding of one skilled in the art from the disclosure provided. The use of cryogenic temperatures necessitates the use of specialized cryogenic piping, which is employed in this embodiment of the present invention. The automatic shutdown feature of the compressor 2712 is illustrative of the various preventative strategies contemplated by the Preferred Embodiment to protect the ice cube's center from cracking due to extreme temperatures. Additionally, the cryogenic pump or compressor can be configured as a remote module, which, in one embodiment, is attached to the transparent ice machine. The present inventor has recognized that this modular approach offers flexibility and enhances the functionality of the ice production system.
Reservoir 2707 holds water 2708. In one embodiment reservoir 2707 is either made from polymer with a thermal conductivity of less than 2 watts per meter-Kelvin or a material having between 14 percent chromium and 28 percent chromium and more preferably between about 15-20 percent and ideally 16 percent chromium, cooper or aluminum. Polymers include but are not limited to high-density polyethylene, low-density or polyethylene, or polyethylene terephthalate, or polycarbonate, or acrylic, or nylon. One embodiment has two or more release openings 2713 or release pipes 2705 for each of the cavities 2710. In one embodiment the released openings 2713 extend into cavities 2710. One embodiment has multiple release openings 2713 where two or more having different diameters. In one embodiment the opening 2713A is positioned facing sidewalls 2703 so water 2708 hits the sidewalls 2703 before hitting bottom wall 2709 when water pump 2706 first starts pumping water 2708 around in cavities 2710. In embodiment water pump 2706 is submersible and agitates water in cavities 2710. In one embodiment this is important because it reduces the size of a dimple or eliminates the dimple in the ice cubes surfaces where warmer water than the ice cube impacts the partially formed ice cube. Ice cube 2710A shows dimple 2710B from water not shown) impacting in direction 2710C. The present invention contemplates all ways to reduce dimpling and all ways fall into the scope of the present invention. The different sized openings are shown by ways of example and not limitation as the Present invention contemplates all ways to provide about the same amount of water out each release opening 2713 and into cavities 2710. In one embodiment cavities 2710 has a substantially flat surface bottom wall. In one embodiment 2700A is configured to provide a superheat of between 3 degrees and 40 degrees during a segment of time the water is being released upwards into cavities 2710. Most ice cube makers use a superheat of 2 degrees F. In one embodiment of the present invention water 2708 is adjusted or held at a temperature with temperature regulator 2714. Regulator 2714 is shown by way of example and not limitation as the Present invention contemplates all ways to keep the temperature regulated in reservoir 2707 such as configuring the refrigeration system and other components together so when water 2708 in the reservoir 2707 contacts bottom wall 2709 water 2708 cools to 70 degrees Fahrenheit and more preferably less than about 60 degrees Fahrenheit in reservoir 2707 and most preferably less than 55 degrees Fahrenheit during a segment of time transparent ice maker 2700 is making ice cube 2719. One embodiment the surface area of bottom wall 2709 inside the sidewalls measures between about 6 to 9 square inches in cavities 2710. In one embodiment reservoir 2707 is configured to hold at least the same water volume as each of the cavities 2710. In one embodiment the transparent ice maker 2700A the superheat is set between 10 degrees Fahrenheit and 40 degrees Fahrenheit and the water released has at least enough pressure to contract the bottom wall 2709 and/or one of the sidewalls 2703. Reservoir 2707 is shown by way of example and not limitation as the. In one embodiment the release openings are sized so about the same amount of water 2708 flows out each release opening or flows into cavities 2710. In one embodiment there are two refrigeration pipes 2702 under bottom wall 2709 of cavities 2710 and in one embodiment they are within an area located between two sidewalls 2703. In one embodiment hot gas (not shown) is run through a refrigeration pipe herein to help release an ice cube from a cavity herein. One of ordinary skill in the art would know how to accomplish this goal from this disclosure. All ice cubes shown within this disclosure may be exchanged with another ice cube shown in other embodiments within this disclosure to create different embodiments. Ice cubes made with this embodiment have a center portion that represents at least 30%-85% of the ice cube and that portion is devoid of visible bubbles, visible crystallizing, visible cracks and visible cloudiness and milkiness. The multiple release openings 2713 or a single release opening are food safe. In one embodiment water pump 2706 is submersible and fits into or hangs on the side of any cavity or bin within this disclosure to agitate water. As the water freezes in the cavity or bin or mold herein the submersible water pump 2706 either is manually periodically moved upwards in the water or is moved periodically upwards automatically. From this description one of ordinary skill in the art will know how to accomplish this goal. In one embodiment reservoir 2707 is filled with water that has a calcium carbonate content less than 180 milligrams per liter of water and a combination of the water and the refrigeration pipe sizes and other components of the ice machine are configured so a portion of the water freezes with an energy efficiency of at least 1 pound of ice cubes per 0.245 kilowatt hours of refrigeration system energy. In one embodiment a water pump shown herein has a segment that touches water that is made of food grade material and in one embodiment of the present invention the water pump is made food safe. In one embodiment bin 108 having five walls made of metal and a lid 114 that provides an internal environment so the ice cube does not reach a temperature where the center of the ice cube cracks from thermal shock when the ice cube is in the bin. Cryogenic ice cubes have a Moh hardness between 2.5 and 6. Moh 3 is the hardness of brass and titanium is 6. Therefore in one embodiment it is critical the internal environment of the bin is such to eliminate thermal cracking. One embodiment the water has a calcium carbonate content less than 260 milligrams per liter of the water. The less of a high concentration of calcium carbonate the less milky the transparent ice cube looks until the ice cube lacks total milkiness. In one embodiment the thickness of the amorphous solid material of the bottom wall of a cavity is less than 0.070 inches so to freeze the water through the amorphous solid material to form the ice cube that freezes outward over 1¼ inch from the substantially flat surface.
A cavity in an exemplary embodiment comprises a bottom wall comprising a polymer having a thermal conductivity of less than 0.60 watts per meter-Kelvin. The bottom wall and a refrigeration pipe in such embodiment are configured such that the water freezes through the polymer providing that the ice cube extends the over 1¼ inch from the wall of the cavity, and at least a portion of the ice cube comprises a Moh hardness of 1.6 to 4.
A specific embodiment is described where the bottom wall, item 2709, exhibits a thickness ranging from approximately 1/16th of an inch to about ⅜ths of an inch, with the most optimal thickness being about ¼ of an inch. This precise thickness is crucial as it ensures the proper thermal dynamics required for the ice-making process. In this embodiment, the refrigeration pipe, item 2702, is constructed from a material akin to that of the bottom wall 2709, ensuring uniformity in material properties and thermal behavior. Additionally, the pipe 2705 is innovatively transformed into a water manifold, item 2716, equipped with one or more release openings, item 2715. These openings are designed to release water upward into each of the cavities, item 2710, and in certain configurations, there are two or more release ends, item 2715, for each cavity. This manifold system is instrumental in distributing an equal volume of water to each cavity, or at least four of the cavities, thereby promoting consistency in ice cube formation. The bottom wall of cavity 2710, or any cavities or molds within this embodiment, is characterized by a flat surface. This flatness is essential for ensuring even freezing and the formation of high-quality ice cubes. The space between two adjacent cavities, item 2710, is defined by the thickness of the sidewall, which is meticulously designed to be less than 2 inches, preferably less than 1 inch, and most ideally ½ inch or ¼ inch or less. The proximity of the cavities enhances energy efficiency during the freezing process. In one embodiment, the space between the cavities, as depicted in
In one embodiment an expansion valve in
It is important to note that the components depicted in the figures throughout this disclosure, including the ice cubes themselves, are designed with interchangeability in mind. This flexibility allows for the various components from different embodiments to be combined, creating new and distinct embodiments within the scope of the present invention. The present invention is not limited to the specific configurations shown in the figures but extends to encompass any and all methods that facilitate the automated production of transparent ice cubes. This includes the utilization of conveyors to transport water or ice cubes within the system, microprocessors to control the freezing process and monitor the quality of the ice cubes, and even the application of artificial intelligence to optimize the production parameters and enhance the efficiency of the ice-making process. Such advancements in automation technology are considered integral to the present invention, broadening its applicability and ensuring that the invention remains at the forefront of the ice production industry. All methods and technologies that contribute to the automation of transparent ice cube manufacturing, as described herein, are within the ambit of the present invention.
Pipe stand 2808 has a vibration or oscillation inhibitor 2809, 2809 is shown as a spring. The spring is shown by way of example and not limitation as the present invention contemplates all inhibitors and all inhibitors fall into the scope of the present invention. In most embodiments of the preferred embodiment the piping is insulated and all insulation herein is shown by way of example and not limitation. All ways to insulate the pipe are contemplated by the preferred embodiment and fall within the scope of the present invention.
The present invention encompasses a comprehensive range of methods to maintain both thermal and mechanical communication between refrigeration pipes and the top or bottom walls of all cavities as depicted herein. This ensures that the refrigeration pipes effectively transfer cold to the water within the cavities, facilitating the formation of ice cubes. The methods of securing the refrigeration pipes include, but are not limited to, the use of a welding member, which provides a durable and permanent bond. Chemical bonding is another contemplated method, offering a strong adhesive connection without the need for welding equipment. Additionally, various fastening techniques such as clip fasteners, screw fasteners, bolt fasteners, and nut fasteners are considered, each providing a reliable means of attachment that can be tailored to specific design requirements. Moreover, the invention contemplates the use of a plate wall member and an insulation wall member, which not only secure the refrigeration pipes but also contribute to the insulation of the system, enhancing the efficiency of the freezing process. The placement of the pipe between two member plates is another method within the scope of the invention, providing a secure and stable configuration that maintains the requisite thermal contact as described herein.
An opening, item 3020, is provided to facilitate the removal of this water layer. The present invention encompasses all methods for removing water from atop the ice cube, and these methods are included within its scope. In one embodiment, the refrigeration compressor is tasked with cooling the temperature inside the housing to below 60 degrees Fahrenheit, and more preferably, below 50 degrees Fahrenheit. A cavity within this embodiment includes walls, one of which comprises an amorphous solid material with a thermal conductivity of less than 2 watts per meter-Kelvin and a thickness of less than 0.070 of an inch. This wall forms a seam with a well-organized crystalline lattice structure wall having a thermal conductivity of at least 14 watts per meter-Kelvin. The cavity is further configured with a first and a second opening, both situated near the top of the cavity and above the desired height of the ice cube, allowing water to be drawn in through the first opening into a water pump and expelled through the second opening back into the cavity. In one embodiment a bottom wall of a cavity herein is made of a material from the group consisting of copper, or aluminum, and stainless steel, and a sidewall of the cavity is made from a polymer, and the bottom wall and the sidewall form a seam and is configured to provide a watertight seal.
In association with various embodiments, it is emphasized that both refrigeration pipes and thermoelectric pads are integral components designed to extract heat from water, thereby facilitating the freezing process. The depiction of ice cube freezing within this disclosure serves as an illustrative example and should not be construed as a limitation on the methods employed.
A notable aspect of the preferred embodiment is the utilization of cryogenic freezing, a technique that represents a significant departure from conventional freezing methods. This advanced approach underscores the inventive step and technical enhancement over the prior art. The components detailed throughout this disclosure, including the refrigeration pipes and thermoelectric pads, are presented as examples of the broader inventive concept. The present invention fully encompasses all possible configurations of these components, demonstrating the breadth and depth of the invention's scope. Every component and configuration described herein is considered to be within the ambit of the present invention.
While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. It is not intended that the invention be limited by the specific examples provided within the specification. While the invention has been described with reference to the aforementioned specification, the descriptions and illustrations of the embodiments herein are not meant to be construed in a limiting sense. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. Furthermore, it shall be understood that all aspects of the invention are not limited to the specific depictions, configurations or relative proportions set forth herein which depend upon a variety of conditions and variables. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is therefore contemplated that the invention shall also cover any such alternatives, modifications, variations or equivalents. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby.
This patent application is a continuation-in-part of U.S. patent application Ser. No. 18/356,100 entitled “Energy Efficient High Quality Transparent Ice Cube Maker and Ice Cube” filed Jul. 20, 2023, which is a continuation-in-part of U.S. patent application Ser. No. 18/312,524 entitled, “Method and Apparatus for Mass Producing High Quality Transparent Ice Cubes”, filed May 4, 2023, which is a continuation-in-part application of U.S. patent application Ser. No. 17/969,980, entitled, “Ice Cube Maker and Method for Making High Quality Transparent Ice Cubes”, filed Oct. 20, 2022, which is a continuation-in-part of U.S. patent application Ser. No. 17/741,846, entitled, “Energy Efficient Transparent Ice Cube Maker”, filed May 11, 2022, which is a continuation-in-part of U.S. patent application Ser. No. 16/974,284, entitled, “Clear ice cube making device,” filed Dec. 16, 2020, which claims the benefits of U.S. Provisional Patent Application No. 63/102,512, entitled, “Popsicle device,” filed Jun. 19, 2020, which are incorporated herein by reference in their entireties.
| Number | Date | Country | |
|---|---|---|---|
| 63102512 | Jun 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 18356100 | Jul 2023 | US |
| Child | 18648668 | US | |
| Parent | 18312524 | May 2023 | US |
| Child | 18356100 | US | |
| Parent | 17969980 | Oct 2022 | US |
| Child | 18312524 | US | |
| Parent | 17741846 | May 2022 | US |
| Child | 17969980 | US | |
| Parent | 16974284 | Dec 2020 | US |
| Child | 17741846 | US |
