U.S. patent application number 15/989387 was filed with the patent office on 2019-11-28 for ice making assemblies and methods for making clear ice.
The applicant listed for this patent is Haier US Appliance Solutions, Inc.. Invention is credited to Justin Tyler Brown, Samuel Vincent DuPlessis, Ronald Scott Tarr.
Application Number | 20190360736 15/989387 |
Document ID | / |
Family ID | 68614350 |
Filed Date | 2019-11-28 |
United States Patent
Application |
20190360736 |
Kind Code |
A1 |
DuPlessis; Samuel Vincent ;
et al. |
November 28, 2019 |
ICE MAKING ASSEMBLIES AND METHODS FOR MAKING CLEAR ICE
Abstract
Ice making assemblies and methods for making ice, and
particularly clear ice, are provided herein. The methods of making
ice may include providing a volume of water within a mold cavity
defined by an ice mold. The volume of water may be demineralized.
Additionally or alternatively, the mold cavity may be pre-chilled
to a sub-freezing temperature. Also additionally or alternatively,
a freezer chamber in which the ice mold is provided may be directed
to one or more sub-freezing temperatures while the volume of water
is within the mold cavity.
Inventors: |
DuPlessis; Samuel Vincent;
(Louisville, KY) ; Brown; Justin Tyler;
(Louisville, KY) ; Tarr; Ronald Scott;
(Louisville, KY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Haier US Appliance Solutions, Inc. |
Wilmington |
DE |
US |
|
|
Family ID: |
68614350 |
Appl. No.: |
15/989387 |
Filed: |
May 25, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F25C 1/22 20130101; F25D
17/06 20130101; F25C 2700/12 20130101; F25C 2600/04 20130101; F25C
1/20 20130101; F25C 2600/02 20130101 |
International
Class: |
F25C 1/20 20060101
F25C001/20 |
Claims
1. A method of making ice comprising: providing a volume of water
within a mold cavity defined within an insulated ice mold, the
insulated ice mold being positioned within a freezer chamber, the
insulated ice mold comprising an insulated sidewall defining a
vertical opening in fluid communication between the freezer chamber
and the mold cavity; maintaining the freezer chamber below a first
sub-freezing temperature during an ice formation cycle as a portion
of the volume of water freezes to a frozen volume; and directing
the freezer chamber to a second sub-freezing temperature during an
ice maintenance cycle while the frozen volume remains within the
freezer chamber, the second sub-freezing temperature being above
the first sub-freezing temperature, the ice maintenance cycle being
subsequent to the ice formation cycle.
2. The method of claim 1, further comprising directing an active
airflow across the insulated ice mold.
3. The method of claim 2, wherein the active airflow is motivated
at a predetermined flow rate during the ice formation cycle.
4. The method of claim 2, wherein the active airflow is motivated
at a variable flow rate during the ice formation cycle.
5. The method of claim 4, wherein the variable flow rate is set
according to a user input.
6. The method of claim 4, wherein the variable flow rate is set
automatically according to a sensed condition at the insulated ice
mold.
7. The method of claim 2, wherein the active airflow is halted
during the ice maintenance cycle.
8. The method of claim 1, wherein the ice formation cycle ends upon
a predetermined time elapsing.
9. The method of claim 1, wherein the ice formation cycle ends upon
a predetermined condition being detected at the insulated ice
mold.
10. A method of making ice comprising: providing a demineralized
volume of water; dissolving a nucleation additive within the
demineralized volume of water to generate a treated volume of
water; providing the treated volume of water within a mold cavity
of an ice mold positioned within a freezer chamber; and freezing a
portion of the treated volume of water within the mold cavity.
11. The method of claim 10, wherein dissolving the nucleation
additive comprises setting a concentration of the nucleation
additive within the treated volume of water to a predetermined
level.
12. The method of claim 10, wherein the nucleation additive
comprises sodium chloride.
13. The method of claim 12, wherein dissolving the nucleation
additive comprises setting a concentration of sodium chloride
within the treated volume of water to a predetermined level,
wherein the predetermined level is between fifty parts per million
of total dissolved solids and one hundred parts per million of
total dissolved solids.
14. The method of claim 10, wherein the mold cavity is defined
within the ice mold to extend from an upper portion to a bottom
portion, and wherein an active cooling system is positioned in
thermal communication with the ice mold to selectively draw heat
therefrom.
15. The method of claim 14, wherein the ice mold further defines a
seed column extending below the mold cavity in fluid communication
therewith, and wherein the seed column has a horizontal width and a
vertical length at least twice as long as the horizontal
diameter.
16. The method of claim 14, further comprising agitating the ice
mold below the upper portion of the mold cavity following providing
the treated volume of water.
17. A method of making ice comprising: chilling an ice mold
defining a mold cavity to a sub-freezing temperature within a
freezer chamber; providing a volume of water within the mold
cavity; and initiating seed crystal formation at a bottom portion
of the mold cavity after providing the volume of water within the
mold cavity.
18. The method of claim 17, wherein initiating seed crystal
formation comprises providing a portion of the volume of water
within a seed column extending below the mold cavity in fluid
communication therewith.
19. The method of claim 17, wherein the ice mold comprises an inner
surface defining the mold cavity and an outer surface facing away
from the mold cavity, and wherein initiating seed crystal formation
comprises striking the inner surface.
20. The method of claim 17, wherein the ice mold comprises an inner
surface defining the mold cavity and an outer surface facing away
from the mold cavity, and wherein initiating seed crystal formation
comprises striking the outer surface.
Description
FIELD OF THE INVENTION
[0001] The present subject matter relates generally to ice making
appliances and methods, and more particularly to appliances and
methods for making substantially clear ice.
BACKGROUND OF THE INVENTION
[0002] In domestic and commercial applications, ice is often formed
as solid cubes, such as crescent cubes or generally rectangular
blocks. The shape of such cubes is often dictated by the
environment during a freezing process. For instance, an ice maker
can receive liquid water, and such liquid water can freeze within
the ice maker to form ice cubes. In particular, certain ice makers
include a freezing mold that defines a plurality of cavities. The
plurality of cavities can be filled with liquid water, and such
liquid water can freeze within the plurality of cavities to form
solid ice cubes.
[0003] In typical ice making appliances, water in the cavities
begins to freeze and solidify first from its sides and outer
surfaces (including a top water surface that may be directly
exposed to freezing air), and then in and through the remaining
volume of water occupying the cavity. In other words, the exterior
surfaces of an ice cube freeze first. However, impurities and gases
contained within the water to be frozen may be trapped in a
solidified ice cube during the freezing process. For example,
impurities and gases may be trapped near the center or the bottom
surface of the ice cube, due to their inability to escape and as a
result of the freezing liquid to solid phase change of the ice cube
surfaces. Separate from or in addition to the trapped impurities
and gases, a dull or cloudy finish may form on the exterior
surfaces of an ice cube (e.g., during rapid freezing of the ice
cube). Generally, a cloudy or opaque ice cube is the resulting
product of typical ice making appliances.
[0004] Although typical ice cubes may be suitable for a number
uses, such as temporary cold storage and rapid cooling of liquids
in a wide range of sizes, they may present a number of
disadvantages. As an example, impurities and gases trapped within
an ice cube may impart undesirable flavors into a beverage being
cooled (i.e., a beverage in which the ice cube is placed) as the
ice cube melts. Such impurities and gases may also cause an ice
cube to melt unevenly or faster (e.g., by increasing the exposed
surface area of the ice cube). Evenly-distributed or slow melting
of ice may be especially desirable in certain liquors or cocktails.
Additionally or alternatively, it has been found that substantially
clear ice cubes (e.g., free of any visible impurities or dull
finish) may provide a unique or upscale impression for the
user.
[0005] Accordingly, further improvements in the field of ice making
would be desirable. In particular, it may be desirable to provide
an appliance or methods for rapidly and reliably producing
substantially clear ice.
BRIEF DESCRIPTION OF THE INVENTION
[0006] Aspects and advantages of the invention will be set forth in
part in the following description, or may be obvious from the
description, or may be learned through practice of the
invention.
[0007] In exemplary aspects of the present disclosure, a method of
making ice is provided. The method of making ice may include
providing a volume of water within a mold cavity defined within an
insulated ice mold, the insulated ice mold being positioned within
a freezer chamber, the insulated ice mold comprising an insulated
sidewall defining a vertical opening in fluid communication between
the freezer chamber and the mold cavity; maintaining the freezer
chamber below a first sub-freezing temperature during an ice
formation cycle as a portion of the volume of water freezes to a
frozen volume; and directing the freezer chamber to a second
sub-freezing temperature during an ice maintenance cycle while the
frozen volume remains within the freezer chamber, the second
sub-freezing temperature being above the first sub-freezing
temperature, the ice maintenance cycle being subsequent to the ice
formation cycle.
[0008] In exemplary aspects of the present disclosure, a method of
making ice is provided. The method of making ice may include
providing a demineralized volume of water; dissolving a nucleation
additive within the demineralized volume of water to generate a
treated volume of water; providing the treated volume of water
within a mold cavity of an ice mold positioned within a freezer
chamber; and freezing a portion of the treated volume of water
within the mold cavity.
[0009] In still other exemplary aspects of the present disclosure,
a method of making ice is provided. The method of making ice may
include chilling an ice mold defining a mold cavity to a
sub-freezing temperature within a freezer chamber; providing a
volume of water within the mold cavity; and initiating seed crystal
formation at a bottom portion of the mold cavity after providing
the volume of water within the mold cavity.
[0010] These and other features, aspects and advantages of the
present invention will become better understood with reference to
the following description and appended claims. The accompanying
drawings, which are incorporated in and constitute a part of this
specification, illustrate embodiments of the invention and,
together with the description, serve to explain the principles of
the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] A full and enabling disclosure of the present invention,
including the best mode thereof, directed to one of ordinary skill
in the art, is set forth in the specification, which makes
reference to the appended figures.
[0012] FIG. 1 provides a side plan view of an ice making appliance
according to exemplary embodiments of the present disclosure.
[0013] FIG. 2 provides a schematic view of an ice making assembly
according to exemplary embodiments of the present disclosure.
[0014] FIG. 3 provides a cross-sectional schematic view of a
portion of an ice making assembly according to exemplary
embodiments of the present disclosure.
[0015] FIG. 4 provides a schematic view of a water distribution
assembly for an ice making assembly according to an example
embodiment of the present disclosure.
[0016] FIG. 5 provides a cross-sectional view of an ice mold
according to exemplary embodiments of the present disclosure.
[0017] FIG. 6 provides a magnified view of a portion of the
exemplary ice mold of FIG. 5.
[0018] FIG. 7 provides a cross-sectional view of an ice mold
according to exemplary embodiments of the present disclosure.
[0019] FIG. 8 provides a cross-sectional view of an ice mold
according to exemplary embodiments of the present disclosure.
[0020] FIG. 9 provides a flow chart illustrating a method of
operating an ice making appliance in accordance with an exemplary
embodiment of the present disclosure.
[0021] FIG. 10 provides a flow chart illustrating a method of
operating an ice making appliance in accordance with an exemplary
embodiment of the present disclosure.
[0022] FIG. 11 provides a flow chart illustrating a method of
operating an ice making appliance in accordance with an exemplary
embodiment of the present disclosure.
DETAILED DESCRIPTION
[0023] Reference now will be made in detail to embodiments of the
invention, one or more examples of which are illustrated in the
drawings. Each example is provided by way of explanation of the
invention, not limitation of the invention. In fact, it will be
apparent to those skilled in the art that various modifications and
variations can be made in the present invention without departing
from the scope or spirit of the invention. For instance, features
illustrated or described as part of one embodiment can be used with
another embodiment to yield a still further embodiment. Thus, it is
intended that the present invention covers such modifications and
variations as come within the scope of the appended claims and
their equivalents.
[0024] Reference will now be made in detail to present embodiments
of the invention, one or more examples of which are illustrated in
the accompanying drawings. The detailed description uses numerical
and letter designations to refer to features in the drawings. Like
or similar designations in the drawings and description have been
used to refer to like or similar parts of the invention. As used
herein, the terms "first," "second," and "third" may be used
interchangeably to distinguish one component from another and are
not intended to signify location or importance of the individual
components. The terms "upstream" and "downstream" refer to the
relative flow direction with respect to fluid flow in a fluid
pathway. For example, "upstream" refers to the flow direction from
which the fluid flows, and "downstream" refers to the flow
direction to which the fluid flows. The terms "includes" and
"including" are intended to be inclusive in a manner similar to the
term "comprising." Similarly, the term "or" is generally intended
to be inclusive (i.e., "A or B" is intended to mean "A or B or
both").
[0025] Turning now to the figures, FIG. 1 provides a side plan view
of an ice making appliance 100, including an ice making assembly
102. FIG. 2 provides a schematic view of ice making assembly 102.
FIG. 3 provides a cross-sectional schematic view of a portion of
ice making assembly 102.
[0026] Generally, ice making appliance 100 includes a cabinet 102
(e.g., insulated housing) and defines a mutually orthogonal
vertical direction V, lateral direction, and transverse direction.
The lateral direction and transverse direction may be generally
understood to be horizontal directions H. As shown, cabinet 102
defines one or more chilled chambers, such as a freezer chamber
106. In certain embodiments, such as those illustrated by FIG. 1,
ice making appliance 100 is understood to be formed as, or as part
of, a stand-alone freezer appliance. It is recognized, however,
that additional or alternative embodiments may be provided within
the context of other refrigeration appliances. For instance, the
benefits of the present disclosure may apply to any type or style
of a refrigerator appliance (e.g., a top mount refrigerator
appliance, a bottom mount refrigerator appliance, a side-by-side
style refrigerator appliance, etc.) that includes a freezer
chamber. Consequently, the description set forth herein is for
illustrative purposes only and is not intended to be limiting in
any aspect to any particular chamber configuration.
[0027] Ice making appliance 100 generally includes an ice making
assembly 102 on or within freezer chamber 106. In some embodiments,
ice making appliance 100 includes a door 105 that is rotatably
attached to cabinet 102 (e.g., at a top portion thereof). As would
be understood, door 105 may selectively cover an opening defined by
cabinet 102. For instance, door 105 may rotate on cabinet 102
between an open position (not pictured) permitting access to
freezer chamber 106 and a closed position (FIG. 2) restricting
access to freezer chamber 106.
[0028] A user interface panel 108 is provided for controlling the
mode of operation. For example, user interface panel 108 may
include a plurality of user inputs (not labeled), such as a
touchscreen or button interface, for selecting a desired mode of
operation. Operation of ice making appliance 100 can be regulated
by a controller 110 that is operatively coupled to user interface
panel 108 or various other components, as will be described below.
User interface panel 108 provides selections for user manipulation
of the operation of ice making appliance 100 such as (e.g.,
selections regarding chamber temperature, ice making speed, or
other various options). In response to user manipulation of user
interface panel 108 or one or more sensor signals, controller 110
may operate various components of the ice making appliance 100 or
ice making assembly 102.
[0029] Controller 110 may include a memory and one or more
microprocessors, CPUs or the like, such as general or special
purpose microprocessors operable to execute programming
instructions or micro-control code associated with operation of ice
making appliance 100. The memory may represent random access memory
such as DRAM, or read only memory such as ROM or FLASH. In one
embodiment, the processor executes programming instructions stored
in memory. The memory may be a separate component from the
processor or may be included onboard within the processor.
Alternatively, controller 110 may be constructed without using a
microprocessor (e.g., using a combination of discrete analog or
digital logic circuitry; such as switches, amplifiers, integrators,
comparators, flip-flops, AND gates, and the like; to perform
control functionality instead of relying upon software).
[0030] Controller 110 may be positioned in a variety of locations
throughout ice making appliance 100. In optional embodiments,
controller 110 is located within the user interface panel 108. In
other embodiments, the controller 110 may be positioned at any
suitable location within ice making appliance 100, such as for
example within cabinet 102. Input/output ("I/O") signals may be
routed between controller 110 and various operational components of
ice making appliance 100. For example, user interface panel 108 may
be in communication with controller 110 via one or more signal
lines or shared communication busses.
[0031] As illustrated, controller 110 may be in communication with
the various components of ice making assembly 102 and may control
operation of the various components. For example, various valves,
switches, etc. may be actuatable based on commands from the
controller 110. As discussed, user interface panel 108 may
additionally be in communication with the controller 110. Thus, the
various operations may occur based on user input or automatically
through controller 110 instruction.
[0032] As will be described in detail below, ice making appliance
100 includes a sealed cooling system 112 for executing a vapor
compression cycle for cooling air within ice making appliance 100
(e.g., within freezer chamber 106). Sealed cooling system 112
includes a compressor 114, a condenser 116, an expansion device
118, and an evaporator 120 connected in fluid series and charged
with a refrigerant. As will be understood by those skilled in the
art, sealed cooling system 112 may include additional components
(e.g., at least one additional evaporator, compressor, expansion
device, or condenser). Moreover, at least one component (e.g.,
evaporator 120) is provided in thermal communication with freezer
chamber 106 to cool the air or environment within freezer chamber
106. Optionally, evaporator 120 is mounted within freezer chamber
106, as generally illustrated in FIG. 1.
[0033] Within sealed cooling system 112, gaseous refrigerant flows
into compressor 114, which operates to increase the pressure of the
refrigerant. This compression of the refrigerant raises its
temperature, which is lowered by passing the gaseous refrigerant
through condenser 116. Within condenser 116, heat exchange with
ambient air takes place so as to cool the refrigerant and cause the
refrigerant to condense to a liquid state.
[0034] Expansion device (e.g., a mechanical valve, capillary tube,
electronic expansion valve, or other restriction device) 118
receives liquid refrigerant from condenser 116. From expansion
device 118, the liquid refrigerant enters evaporator 120. Upon
exiting expansion device 118 and entering evaporator 120, the
liquid refrigerant drops in pressure and vaporizes. Due to the
pressure drop and phase change of the refrigerant, evaporator 120
is cool relative to freezer chamber 106. As such, cooled air is
produced and refrigerates freezer chamber 106. Thus, evaporator 120
is a heat exchanger which transfers heat from air passing over
evaporator 120 to refrigerant flowing through evaporator 120.
[0035] Optionally, ice making appliance 100 further includes a
valve 122 for regulating a flow of liquid water to ice making
assembly 102. Valve 122 is selectively adjustable between an open
configuration and a closed configuration. In the open
configuration, valve 122 permits a flow of liquid water to ice
making assembly 102. Conversely, in the closed configuration, valve
122 hinders the flow of liquid water to an ice mold 130.
[0036] In certain embodiments, ice making appliance 100 also
includes an air handler 124 mounted within (or otherwise in fluid
communication with) freezer chamber 106. Air handler 124 may be
operable to urge a flow of chilled air (i.e., active airflow--as
indicated at arrows 126) within freezer chamber 106. Moreover, air
handler 124 can be any suitable device for moving air. For example,
air handler 124 can be an axial fan or a centrifugal fan.
[0037] As shown, an ice mold 130 may be provided within freezer
chamber 106. In particular, ice mold 130 may be removably
positioned within freezer chamber 106 such that a user may
selectively place ice mold 130 within freezer chamber 106 (e.g.,
during ice making operations) and remove ice mold 130 from freezer
chamber 106 (e.g., to remove ice billets from ice mold 130) as
desired. As shown, ice mold 130 includes one or more sidewalls 132
that define one or more mold cavities 134 in which water may be
received and ice cubes or billets (e.g., solid masses or blocks of
ice that may be further melted to a final shape) may be formed.
Optionally, the mold cavities 134 may be defined as open voids in
fluid communication with freezer chamber 106. For instance, the
sidewalls 132 may define a vertical opening 140 corresponding to
each mold cavity 134 through which air or water may pass. The
vertical opening 140 may, for example, have a horizontal diameter
that is equal to or greater than the horizontal diameter of the
mold cavity 134. A base wall 142 may extend below the sidewalls 132
to further define mold cavities 134 and, for example, ensure that
water does not leak or pass from mold cavity 134 (e.g., during ice
making operations).
[0038] Generally, it is understood that ice mold 130 may be formed
from any suitable material. In some embodiments, one or more
thermally insulating materials are utilized to form ice mold 130.
The sidewalls 132 may be insulated sidewalls 132 and the ice mold
130 may be an insulated ice mold 130. As an example, one or more of
the sidewalls 132 may define a sealed insulation volume. The sealed
insulation volume may generally prevent the passage of air or
oxygen to or from a volume within each sidewall 132 (e.g., as a
substantially evacuated a vacuum or a volume filled with a set mass
of gas, such as nitrogen, oxygen, argon, or a suitable inert gas).
As another example, one or more of the sidewalls 132 may be formed
or filled with a solid insulating material (e.g., a rigid
polyurethane insulating foam) to hinder to heat transfer between
each mold cavity 134 and its surrounding environment (e.g., freezer
chamber 106).
[0039] When assembled, air handler 124 may be positioned above (or
otherwise located at a position to) direct an active airflow 126
across a top portion of ice mold 130 (e.g., perpendicular to
vertical opening 140). Thus, an active airflow 126 may be
selectively motivated across ice mold 130, thereby accelerating
heat transfer from ice mold 130 at the top portion thereof. For
instance, air handler 124 may be configured to motivate the active
airflow 126 at one or more predetermined flow rates (e.g.,
volumetric flow rates) within freezer chamber 106.
[0040] In some embodiments, one or more sensors are mounted on or
within ice mold 130. As an example, a temperature sensor 144 may be
mounted to ice mold 130. Temperature sensor 144 may be electrically
coupled to controller 110 and configured to detect the temperature
within ice mold 130. Temperature sensor 144 may be formed as any
suitable temperature detecting device, such as a thermocouple,
thermistor, etc. Optionally, temperature sensor 144 may be mounted
at a predetermined height along one of the sidewalls 132. In some
such embodiments, the predetermined height is a ballast height 148
positioned below the top portion of ice mold 130.
[0041] During use (e.g., during ice making operations), a liquid
ballast 150 may form on top of a frozen volume (e.g., ice cube or
billet) within mold cavity 134. Advantageously, impurities within
the volume of water from which the frozen volume is formed may
accumulate within the liquid ballast 150 as the volume of water
freezes. Detection of a predetermined temperature at the
temperature sensor 144 (e.g., at the ballast height 148) may
indicate the frozen volume has reached the ballast height 148.
Optionally, controller 110 may be configured to adjust one or more
operations of the ice making assembly 102 in response to
determining that the ice mold 130 has frozen to the ballast height
148.
[0042] In additional or alternative embodiments, a pressure sensor
146 is mounted to ice mold 130. Pressure sensor 146 may be formed
as any suitable pressure detecting device, such as a
piezoresistive, capacitive, electromagnetic, piezoelectric, or
optical pressure detecting device. During use, detection of a
predetermined pressure increase at the pressure sensor 146 (i.e.,
at the ballast height 148) may indicate that a desired portion of
the volume of water within mold cavity 134 has frozen (i.e., become
a frozen volume). Optionally, controller 110 may be configured to
adjust one or more operations of the ice making assembly 102 in
response to determining the predetermined pressure increase has
been reached.
[0043] In optional embodiments, a removable sleeve 152 is provided
for selective insertion/removal within mold cavity 134. As shown,
removable sleeve 152 may shaped to generally complement the
surfaces of sidewalls 132 and base wall 142 that define mold cavity
134. Removable sleeve 152 may thus form a complementary opening to
vertical opening 140. During use, a volume of water may be provided
to removable sleeve 152 and ice may be formed therein (i.e., as the
volume of water transitions to a frozen volume). Once a volume of
water is frozen (e.g., as an ice cube or billet), removable sleeve
152 and the frozen volume may be removed together from ice mold
130.
[0044] Turning now to FIG. 4, a schematic view of an example water
distribution assembly 154 is provided. Water distribution assembly
154 may be included with or as part of ice making assembly 102
(FIG. 3), as described above. In some such embodiments, ice making
operations include providing or flowing water from a water
distribution assembly 154 and to ice mold 130 (e.g., within mold
cavity 134--FIG. 3).
[0045] In certain embodiments, a prefilter cartridge 160 or divider
valve 162 are positioned upstream of ice mold 130. Prefilter
cartridge 160 may be an activated carbon filter configured to
remove sediment or organic material from water supplied thereto.
Water received from a water source 164 (e.g., domestic water grid
or well) may thus be forced through prefilter cartridge 160 before
being directed to ice making assembly 102.
[0046] In optional embodiments, water may be introduced to water
reservoir 166 (e.g., mounted on cabinet 102, within cabinet 102, or
at another location spaced apart from cabinet 102--FIG. 1). A water
recirculation line 168 may generally extend between water reservoir
166 or water source 164 and ice mold 130. Optionally, water
recirculation line 168 may extend into the volume defined by water
reservoir 166. Water recirculation line 168 may further extend in
fluid communication between water reservoir 166 and water
distribution outlet or manifold 170. In some such embodiments, a
pump 172 is positioned along water recirculation line 168 to
motivate water from within reservoir 166 to water distribution
manifold 170 through water recirculation line 168. Additionally or
alternatively, valve 122 (FIG. 2) may be provided in fluid
communication between water source 164 and manifold 170 (e.g., with
or without reservoir 166, pump 172, or any other portion of water
distribution assembly 154) to control the flow of water to ice mold
130.
[0047] In some embodiments, a deionization filter 174 is positioned
along water recirculation line 168. For instance, deionization
filter 174 may be positioned upstream from the water distribution
manifold 170 (e.g., in fluid communication therewith). Deionization
filter 174 is generally configured to demineralize water or
otherwise remove dissolved solids, such as inorganic salts of
sodium and chlorine ions. Moreover, deionization filter 174 may
include an anion resin and a cation resin. Optionally, deionization
filter 174 may be a mixed-bed filter wherein the anion and cation
resins are commingled.
[0048] In some embodiments, an organic compound filter 176 is
positioned in fluid communication with ice mold 130 (e.g., as an
activated carbon filter). Organic compound filter 176 may be in
fluid communication between the deionization filter 174 and the
water distribution manifold 170. In other words, organic compound
filter 176 may be downstream from deionization filter 176.
Optionally, organic compound filter 176 may be contained within the
same filtration cartridge as deionization filter 174.
Alternatively, organic compound filter 176 may include a discrete
cartridge body spaced apart from deionization filter 174 along
water recirculation line 168.
[0049] As illustrated, one or more conductivity sensors 180 may be
provided in fluid communication with the water source 164. For
instance, a conductivity sensor 180 may be positioned along water
recirculation line 168 (e.g., downstream of deionization filter 174
or organic compound filter 176). Conductivity sensor 180 may be
operably connected (e.g., electrically coupled) to controller 110.
Moreover, conductivity sensor 180 may be configured to detect a
value of fluid conductivity of water within assembly. Based on
conductivity values detected at conductivity sensor 180, controller
110 may determine that deionization filter 174 has reached the end
of a filter lifecycle (e.g., and should be replaced). Optionally,
controller 110 may be configured to automatically halt ice making
assembly 102 or ice making operations according to one or more
conductivity values detected at conductivity sensor 180. For
instance, if controller 110 determines that a detected conductivity
value exceeds a threshold conductivity value, controller 110 may
halt or cease operation of ice making assembly 102 (FIG. 3)--e.g.,
at water distribution assembly 154.
[0050] In some embodiments, an additive dispenser 178 is provided
in fluid communication with the water source 164. For instance,
additive dispenser 178 may be positioned along water recirculation
line 168, downstream from the filters 174, 176 and upstream from
ice mold 130 (e.g., and manifold 170). Additive dispenser 178 may
be configured to selectively add or incorporate nucleation additive
within the water flowed to ice mold 130. For instance, additive
dispenser 178 may be electrically coupled to controller 110.
Controller 110 may be configured to direct additive dispenser 178
to release nucleation additive to the flow of water (e.g., such
that a predetermined concentration of nucleation additive is
reached within a volume of water (e.g., before it enters ice mold
130). In some embodiments, the nucleation additive is provided as a
salt (e.g., sodium chloride) in, for instance, a suitable granular
or liquid solution form.
[0051] Turning now to FIGS. 5 and 6, various views are provided of
an ice mold 130 according to exemplary embodiments. As shown, mold
cavity 134 generally extends from an upper portion 136 to a bottom
portion 138. In some such embodiments, ice mold 130 includes
multiple discrete mold bodies. For instance, a first mold body 182
and a second mold body 184 may be provided. Generally, first mold
body 182 defines a first cavity portion 186 and second mold body
184 defines a second cavity portion 188. Although first and second
mold bodies 182, 184 may be selectively separated (e.g., to remove
an ice cube or billet from ice mold 130), when assembled, second
cavity portion 188 is axially aligned (e.g., along the vertical
direction V) with the first cavity portion 186. Thus, first and
second cavity portions 186, 188 together define mold cavity 134.
The vertical opening 140 may be defined above first and second
cavity portions 186, 188 (e.g., in axial alignment therewith). When
ice mold 130 is positioned within freezer chamber 106 (FIG. 1),
vertical opening 140 or mold cavity 134 may be in fluid
communication between mold cavity 134 and the freezer chamber
106.
[0052] In optional embodiments, first and second mold bodies 182,
184 are formed from a conductive material (e.g., stainless steel,
aluminum, etc., including alloys thereof). In additional or
alternative embodiments, one or more portions of the sealed cooling
system 112 are in thermal communication with one or both of the
mold bodies 182, 184 to selectively draw heat therefrom. In
particular, the evaporator 120 may be in thermal communication
(e.g., direct conductive contact, spaced apart direct engagement,
etc.) with first mold body 182. For instance, first mold body 182
may be positioned on or above evaporator 120 such that heat is
conducted from mold cavity 134 through first mold body 182 and to
evaporator 120.
[0053] In certain embodiments, a seed column 190 is defined within
ice mold 130. For instance, seed column 190 may be defined in fluid
communication with mold cavity 134, such that a portion of the
volume of water provided to mold cavity 134 may pass into the seed
column 190. As shown, seed column 190 generally defines a fluid
channel extending from (e.g., below) mold cavity 134. As an
example, seed column 190 may extend downward (e.g., in the vertical
direction V) from the bottom portion 138 of mold cavity 134. Seed
column 190 may define a cross-sectional or horizontal width W
(e.g., diameter perpendicular to the vertical direction V). A
length E of the seed column 190 may be defined perpendicular to the
horizontal width W (e.g., parallel to the vertical direction V). In
some such embodiments, the length E is greater than horizontal
width W. For instance, the length E may be at least twice as long
as the horizontal width W. Optionally, the horizontal width W may
be less than 0.125 inch (e.g., while still being large enough to
permit liquid water therethrough under the force of gravity).
[0054] Turning now to FIGS. 7 and 8, various views are provided of
an ice mold 130 according to other exemplary embodiments. As shown,
mold cavity 134 generally extends from an upper portion 136 to a
bottom portion 138. In some such embodiments, ice mold 130 includes
multiple discrete mold bodies. For instance, a first mold body 182,
a second mold body 184, and a third mold body 192 may be provided.
Generally, first mold body 182 defines a first cavity portion 186
and second mold body 184 defines a second cavity portion 188.
Although first and second mold bodies 182, 184 may be selectively
separated (e.g., to remove an ice cube or billet from ice mold
130), when assembled, second cavity portion 188 is axially aligned
(e.g., along the vertical direction V) with the first cavity
portion 186. Thus, first and second cavity portions 186, 188
together define mold cavity 134. The vertical opening 140 may be
defined above first and second cavity portions 186, 188 (e.g., in
axial alignment therewith). When ice mold 130 is positioned within
freezer chamber 106 (FIG. 1), vertical opening 140 or mold cavity
134 may be in fluid communication between mold cavity 134 and the
freezer chamber 106.
[0055] As shown, third mold body 192 may be selectively inserted or
positioned within mold cavity 134 (e.g., through vertical opening
140). Third mold body 192 generally extends (e.g., along the
vertical direction V) between an upper surface 194 and a lower
surface 196. When positioned within mold cavity 134, the lower
surface 196 of third mold body 192 may form a complementary recess
198 (e.g., axially aligned with first cavity portion 186 along the
vertical direction V). Optionally, the portion of the lower surface
196, such as a radial edge, may rest on or above the first mold
body 182. In turn, complementary recess 198 and first cavity
portion 186 may generally define a volume or negative of the shape
that an ice cube or billet frozen within mold cavity 134 may
assume.
[0056] In optional embodiments, first, second, and third mold
bodies 182, 184, 186 are formed from a conductive material (e.g.,
stainless steel, aluminum, etc., including alloys thereof). In
additional or alternative embodiments, one or more portions of the
sealed cooling system 112 are in thermal communication with one or
both of the mold bodies 182, 184 to selectively draw heat
therefrom. In particular, the evaporator 120 may be in thermal
communication (e.g., direct conductive contact, spaced apart direct
engagement, etc.) with first mold body 182. For instance, first
mold body 182 may be positioned on or above evaporator 120 such
that heat is conducted from mold cavity 134 through first mold body
182 and to evaporator 120.
[0057] In some embodiments, a striker 210 is selectively engaged
with one or more of the mold bodies 182, 184, 186 (e.g., when
assembled). In particular, striker 210 may be configured to
selectively impact (e.g., collide with) the ice mold 130 to agitate
the mold cavity 134 below the upper portion 136 thereof. Striker
210 may be provided as a rigid element formed from any suitable
material. Thus, the impact of striker 210 on ice mold 130 transfer
a collision or impact force to mold cavity 134.
[0058] As illustrated in FIG. 7, in certain embodiments, striker
210 is positioned outside of mold cavity 134. For instance, striker
210 may be directed towards first mold body 182. Optionally, a
motor or actuator 212 may be mechanically coupled to striker 210
and configured to selectively move striker 210 (e.g., in a linear
direction or horizontal direction H) against an outer surface 216
of first mold body 182. As shown, the outer surface 216 is formed
opposite from the inner surface 214 of the mold cavity 134 and is
directed outward away from the mold cavity 134 (e.g., toward the
surrounding environment). In some such embodiments, actuator 212 is
operably coupled to the controller 110 (FIG. 1) and is configured
to motivate or move striker 210 in response to one or more signals
received from the controller 110. Moving striker 210 against first
mold body 182 may generate a collision or impact force that is thus
transferred through first mold body 182 and, for instance, to the
volume of liquid water within mold cavity 134.
[0059] As illustrated in FIG. 8, in additional or alternative
embodiments, striker 210 is positioned within mold cavity 134. For
instance, striker 210 may be directed through second mold body 184
and third mold body 192 towards an inner surface 214 of first mold
body 182. Optionally, a motor or actuator 212 may be mechanically
coupled to striker 210 and configured to selectively move striker
210 (e.g., in a linear direction or vertical direction V) against
first mold body 182. As an example striker 210 may be selectively
moved against (e.g., impact or collide with) the bottom portion 138
of mold cavity 134. In some such embodiments, actuator 212 is
operably coupled to the controller 110 (FIG. 1) and is configured
to motivate or move striker 210 in response to one or more signals
received from the controller 110. Moving striker 210 against first
mold body 182 may generate a collision or impact force that is thus
transferred, for instance, to the volume of liquid water within
mold cavity 134.
[0060] Referring now to FIGS. 9 through 11, various methods (e.g.,
method 300, method 400, and method 500) may be provided for use
with the ice making appliance 100 or ice making assembly 102 (FIG.
1) in accordance with the present disclosure. In some embodiments,
such as the exemplary embodiments illustrated by methods 300, 400,
and 500 all or some of the various steps of the method may be
performed by controller 110 (FIG. 1). For example, controller 110
may, as discussed, be operably coupled to one or more of sealed
cooling system 112, valve 122, control panel, air handler 124,
pressure sensor 146, temperature sensor 144, additive dispenser
178, or actuator 212. During use, controller 110 may send signals
to or receive signals from some or all of these components.
Controller 110 may further be operably coupled to other suitable
components of the appliance 100 to facilitate operation of the
appliance 100 generally. The present methods may advantageously
facilitate the formation or creation of substantially clear ice
cubes or billets. Moreover, such methods may advantageously permit
substantially clear ice to be produced in less than 14 hours (e.g.,
following initiation thereof).
[0061] FIGS. 9 through 11 depict steps performed in a particular
order for purpose of illustration and discussion. Those of ordinary
skill in the art, using the disclosures provided herein, will
understand that (except as otherwise indicated) the steps of any of
the methods disclosed herein can be modified, adapted, rearranged,
omitted, or expanded in various ways without deviating from the
scope of the present disclosure.
[0062] Turning now to FIG. 9, at 310, the method 300 may include
providing a volume of water within the mold cavity defined within
the ice mold. In some embodiments, the ice mold is an insulated ice
mold. Thus, national may include one or more insulated sidewalls,
as described above. Moreover, the insulated sidewalls may define
vertical opening. The vertical opening may generally be exposed or
uncovered (e.g., relative to surrounding environment). When
positioned within the freezer chamber, the vertical opening may
thus be in fluid communication between freezer chamber and the mold
cavity.
[0063] It is understood that the volume of water provided to the
mold cavity may be provided manually or, alternatively,
automatically. For instance, when provided manually, the volume of
water in mold cavity may be poured directly by a user supplying the
water to mold cavity. By contrast, when provided automatically, the
controller may control or actuate the valve of the ice making
assembly to open, thereby permitting volume of water to flow to the
mold cavity. Additionally or alternatively, the pump of the water
distribution assembly may be activated, as described above.
Although described as automatic, is understood that controller may
operate (e.g., transmit one or more signals to the valve) in
response to one or more user input signals received from the user
interface. Moreover, it is understood that the volume of water may
be provided to the mold cavity while the ice mold is positioned
within or, alternatively, outside of freezer chamber. However, the
purposes of the method 300, once the volume of water is provided
within the mold cavity, the ice mold is understood to be positioned
within the freezer chamber (e.g., for the duration of steps 320 and
330).
[0064] At 320, the method 300 may include maintaining the freezer
chamber below a first sub-freezing temperature during an ice
formation cycle. The ice formation cycle may be performed while the
ice mold (and thereby the volume of water within the mold cavity)
is positioned within the freezer chamber. Thus, the ice mold is
maintained or held below the first sub-freezing temperature for the
duration of the ice formation cycle as a portion of the volume of
water freezes to a frozen volume (e.g., ice cube or billet). During
the ice formation cycle, the freezer chamber may be maintained at a
relatively stable temperature (e.g., between -10.degree. Fahrenheit
and 10.degree. Fahrenheit). In some embodiments, the first
sub-freezing temperature may be 10.degree. Fahrenheit. In other
embodiments, the first sub-freezing temperature may be 5.degree.
Fahrenheit. In further embodiments, the first sub-freezing
temperature may be 0.degree. Fahrenheit.
[0065] As described above, the sealed cooling system may be
activated or otherwise directed to cool the freezer chamber. For
instance, during the ice formation cycle, heat may be drawn from
the freezer chamber or ice mold at the evaporator. As would be
understood, the sealed cooling system may be selectively activated
by the controller (e.g., based on one or more temperature signals
received from a temperature sensor mounted to the ice making
appliance or within the freezer chamber).
[0066] At 330, the method 300 may include directing the freezer
chamber to a second sub-freezing temperature during an ice
maintenance cycle. Generally, 330 is performed subsequent to 320
(e.g., immediately following completion of the ice formation
cycle). Moreover, during 330, the frozen volume is understood to
remain within the freezer chamber (e.g., within the mold cavity or
separate therefrom in a discrete ice container). Thus, the present
volume is maintained or held at the second sub-freezing temperature
for the duration of the maintenance cycle.
[0067] The second sub-freezing temperature may be greater than the
first sub-freezing temperature. In turn, transitioning from the ice
formation cycle to the maintenance cycle may require releasing the
temperature within the freezer chamber. Such an increase may occur
gradually and as a result of natural heat absorption by the ice
making appliance. Optionally, 330 may include deactivating limiting
operation of the sealed cooling system. The sealed cooling system
may continue to draw heat from the freezer chamber (e.g., through
the evaporator), but at a rate less than would be provided during
the ice formation cycle. The second sub-freezing temperature may be
a relatively stable temperature (e.g., between 20.degree.
Fahrenheit and 32.degree. Fahrenheit). In some embodiments, the
first sub-freezing temperature may be 20.degree. Fahrenheit. In
other embodiments, the first sub-freezing temperature may be
25.degree. Fahrenheit. In further embodiments, the first
sub-freezing temperature may be 30.degree. Fahrenheit.
[0068] In some embodiments, 330 is contingent upon completion of
the ice formation cycle. In other words, the method 300 may include
ensuring that the ice formation cycle is complete before initiating
330 and the ice maintenance cycle. Completion of the ice formation
cycle may include determination of one or more predetermined
conditions. As an example, the ice formation cycle may have
predetermined time (e.g., span of time) after which the ice
formation cycle expires. Thus the ice formation cycle may end upon
the predetermined time elapsing. Optionally, the predetermined time
may begin when the volume of water is provided within the freezer
chamber (e.g., at 310). As another example, the ice formation cycle
may end upon a predetermined condition being detected at the ice
mold. Optionally, the predetermined condition may include detecting
a set temperature been reached at the temperature sensor (e.g., at
the ballast height). Detection of the set temperature may indicate
that the frozen volume has reached (i.e., frozen to) the ballast
height and is therefore at a desired size. Additionally or
alternatively, the predetermined condition may include detecting a
set pressure has been reached at the pressure sensor within the ice
mold. Furthermore, it is understood that any other suitable
predetermined condition for ascertaining the size of the frozen
volume or extent to which the provided volume of water has frozen
may be utilized.
[0069] In optional embodiments, method 300 includes directing an
active airflow across the ice mold. For instance, as described
above the air handler within the freezer chamber may be activated
or rotated to motivate air within the freezer chamber to flow
(i.e., as an active airflow) over or across the ice mold. The
active airflow may be provided at one or more periods of the method
300. In particular, the active airflow may be provided at 320 or
for the duration of the ice formation cycle. In some such
embodiments, the active airflow is motivated a predetermined flow
rate (e.g., volumetric flow rate). In other words, the flow rate of
the active airflow may remain constant during the ice formation
cycle. In other embodiments, active airflow is motivated at a
variable flow rate. The flow rate may increase or decrease based
one or more received signals or user inputs. For instance, the
variable flow rate may be set according to a specific user input.
Additionally or alternatively, the variable flow rate may be set
automatically according to a sensed condition (e.g., one or more
signals received from, for example, the temperature sensor or the
pressure sensor mounted to the ice mold).
[0070] Optionally, the active airflow may further be provided at
330 or for the duration of the maintenance cycle (e.g., at a flow
rate that is less than a flow rate during the ice formation cycle).
Alternatively, the active airflow may be halted during 330 or for
the duration of the maintenance cycle.
[0071] Turning now to FIG. 10, at 410, the method 400 may include
providing a demineralized volume of water. For instance, the volume
of water provided at 410 may be distilled water. Additionally or
alternatively, the volume of water provided at 410 may be deionized
water. In some such embodiments, 410 includes directing an initial
volume of water through a deionization filter upstream from the ice
mold, as described above.
[0072] At 420, the method 400 may include dissolving a nucleation
additive within the demineralized volume of water. By dissolving
the nucleation additive within the demineralized volume of water, a
treated volume of water may be generated. The nucleation additive
generally includes sediment or material for promoting ice
nucleation during freezing. As an example, the nucleation additive
may include or be provided as sodium chloride (e.g., in a granular
form or as part of a concentrated solution). In certain
embodiments, 420 includes setting a concentration of the nucleation
additive within the treated volume of water to a predetermined
level. Thus, the amount of nucleation additive dissolved within the
treated volume of water may only be the amount necessary to achieve
the predetermined level (e.g., ratio of nucleation additive to
water). Optionally, the predetermined level may be between 50 parts
per million (ppm) of Total Dissolved Solids (TDS) and 100 ppm of
TDS. Advantageously, the level or amount of nucleation additive
within the water may thus be controlled, regardless of the level or
amount that would otherwise be available in a given geographic
region.
[0073] In some embodiments, 420 includes manually mixing our adding
the nucleation additive to the volume of demineralized water. In
other embodiments, 420 includes automatically adding the nucleation
additive to the volume of demineralized water (e.g., as directed by
the controller). For instance, as described above, the additive
dispenser may selectively direct or supply nucleation additive to
the demineralized water as it is flowed to the ice mold.
[0074] At 430, the method 400 may include providing the treated
volume of water within a mold cavity positioned within a freezer
chamber. Thus, the treated volume of water generated at 420 may be
flowed into the mold cavity and within the freezer chamber.
[0075] At 440, the method 400 may include freezing at least a
portion of the treated volume of water within the mold cavity. In
some such embodiments, freezing at 440 may include directing an ice
formation cycle, as described above (e.g., with respect to the
method 300). Optionally, an ice maintenance cycle may follow the
ice formation cycle, as further described above. Advantageously,
impurities or sediment within the treated volume of water may
settle together at a nucleation site for the ice as it freezes into
a substantially clear ice cube or billet. Moreover, a liquid
ballast may form above a frozen volume within the mold cavity
(e.g., without flash freezing at the subfreezing temperature of the
ice mold). Sediment or impurities provided with the volume of water
may thus accumulate within the liquid ballast (e.g., instead of
within the frozen volume).
[0076] In optional embodiments, the method 400 includes agitating
the ice mold. In particular, the ice mold may be agitated below the
upper portion of the ice mold. The agitation may generally follow
430. Moreover, agitation may initiate nucleation or freezing of the
treated volume of water. In some such embodiments, agitating the
ice mold includes moving or actuating the striker to impact or
collide with a portion of the ice mold (e.g., the first mold body),
as described above.
[0077] Turning now to FIG. 11, at 510, the method 500 may include
chilling the ice mold defining the mold cavity to a sub-freezing
temperature within the freezer chamber. For instance, the sealed
cooling system may be activated to draw heat from the ice mold
within the freezer chamber. In some such embodiments, the sealed
cooling system remains active until after a predetermined
sub-freezing temperature is detected at the ice mold (e.g., by a
temperature sensor mounted therein). In certain embodiments, the
evaporator of the sealed cooling system is mounted in thermal
communication (e.g., conductive contact) with, for example, the
first mold body of the ice mold, as described above. During 510
(e.g., throughout the time period during which the ice mold is
chilling towards a sub-freezing temperature), the mold cavity may
remain substantially empty and free of a volume of water.
[0078] At 520, the method 500 may include providing a volume of
water within the mold cavity. In particular, the volume of water is
not provided until after the sub-freezing temperature is reached at
the ice mold. In other words, the ice mold may be pre-chilled to
the sub-freezing temperature. The volume of water may be poured,
for example, manually or automatically dispensed to the mold
cavity, as described above. The volume of water may be
demineralized or distilled prior to being provided to the mold
cavity. Optionally, the volume of water may be a demineralized or
distilled volume of water when provided to the mold cavity. In
certain embodiments, the volume of water will be prevented from
freezing or nucleating instantly upon entering the mold cavity.
Thus, 520 may include super cooling the volume of water within the
mold cavity.
[0079] At 530, the method 500 may include initiating seed crystal
formation at a bottom portion of the mold cavity after providing
the volume of water within the mold cavity. In other words, 530 may
occur subsequent to 520 or the super cooling of the volume of
water.
[0080] In some embodiments, 530 includes providing a portion (e.g.,
less than all) of the volume of water within a seed column. As
described above, the seed column may be in fluid communication with
the mold cavity and, for example, extend therebelow.
Advantageously, the portion of water within the seed column may
freeze before the remaining volume of water within the mold cavity,
thereby creating a nucleation site from which water within the mold
cavity may freeze. Moreover, a liquid ballast may form above a
frozen volume within the mold cavity (e.g., without flash freezing
at the subfreezing temperature of the ice mold). Sediment or
impurities provided with the volume of water may thus accumulate
within the liquid ballast (e.g., instead of within the frozen
volume).
[0081] In additional or alternative embodiments, 530 includes
striking the inner surface of the ice mold. As described above, the
inner surface forms a portion of the mold cavity. As also described
above, the striker may extend through the mold cavity to
selectively contact (e.g., impact or collide with) the inner
surface to generate an impact force thereon. In particular, the
striker may strike the inner surface of the first mold body and a
bottom portion of the mold cavity (e.g., as motivated by the
actuator). Striking the inner surface may cause the super cooled
volume of water within the mold cavity to begin freezing (e.g., at
the site at which the inner surface is struck), thereby creating a
nucleation site from which water within the mold cavity may
freeze.
[0082] In further additional or alternative embodiments, 530
includes striking the outer surface of the ice mold. As described
above, the outer surface may be directed outward away from the mold
cavity. As also described above, the striker may extend towards and
selectively contact (e.g., impact or collide with) the outer
surface to generate an impact force thereon. In particular, the
striker may strike the outer surface of the first mold body (e.g.,
as motivated by the actuator). Striking the outer surface may cause
the super cooled volume of water within the mold cavity to begin
freezing, thereby creating a nucleation site from which water
within the mold cavity may freeze.
[0083] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they include structural elements that do not
differ from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal languages of the claims.
* * * * *