Apparatus and method for craft ice production

A freezing and cutting assembly and method for producing ice cubes. The freezing and cutting assembly includes a freezing unit configured to freeze a slab of ice. The freezing unit includes a cold plate and a frame removably coupleable to the cold plate. The cutting unit includes at least one heated electrical wire tensioned on a cutting unit frame and configured to divide the slab of ice into ice cubes.

BACKGROUND

The present disclosure relates to ice making, and more particularly to an apparatus and method for making clear craft ice. Clear craft ice may have many different uses, such as but not limited to consumption in craft beverages.

The present disclosure also relates to an apparatus and method for producing and dividing a relatively thick ice slab into ice cubes. Known methods for dividing a relatively thick ice slab into ice cubes include using a saw blade (e.g., a blade such as metal having a serrated cutting edge or other tooth form, or other type of abrasive cutting edge, for mechanical material removal) to cut through the thick slab. For producing smaller ice cubes from a smaller slab having a relatively small thickness, the Monogram™ Under-the Counter Icemaker by GE divides a small slab of ice having a thickness of about 0.5 inches into ice cubes using a cutter grid. The Monogram™ Under-the Counter Icemaker Service Guide identifies that a problem is present if the ice slab has a thickness of ¾ inches or larger (p. 38, Table, Col. 1) with probable causes including scale buildup, defective or disconnected hot gas valve, and room temperature over 100 degrees Fahrenheit (id, Col. 2).

SUMMARY

Using heat from an electric wire to divide an ice slab causes melting of frozen ice into meltwater. Known usage of electric wires to divide ice is limited to small, shallow ice slabs having a thickness of less than ¾ inches, thereby minimizing meltwater volume. Thicker ice slabs, such as those having a thickness of at least 1 inch, present challenges to the heated cutting method because of increased volume of meltwater as a result of a longer dividing process. Meltwater can refreeze and cause divided ice cubes to clump together.

In one aspect, the disclosure provides a freezing and cutting assembly for producing ice cubes. The freezing and cutting assembly includes a freezing unit configured to freeze a slab of ice. The freezing unit includes a cold plate and a frame removably coupleable to the cold plate. The cutting unit includes at least one heated electrical wire tensioned on a cutting unit frame and configured to divide the slab of ice into ice cubes.

In another aspect, the disclosure provides a freezing and cutting assembly for producing ice cubes. The freezing and cutting assembly includes a freezing unit configured to freeze a slab of ice, and a cutting unit configured to receive the slab of ice from the freezing unit. The cutting unit includes at least one heated electrical wire tensioned on a cutting unit frame and configured to divide the slab of ice into ice cubes. The freezing and cutting assembly also includes a tray configured to receive the ice cubes from the cutting unit. The tray includes dividers configured to separate the ice cubes from each other.

In yet another aspect, the disclosure provides a freezing and cutting assembly for producing ice cubes. The freezing and cutting assembly includes a first freezing unit configured to form primary slabs of ice, a second freezing unit configured to form secondary slabs of ice, and a cutting unit configured to alternatingly receive the primary and secondary slabs of ice from the first and second freezing units. The cutting unit is configured to divide each of the primary and secondary slabs of ice into ice cubes.

In yet another aspect, the disclosure provides a method for producing ice cubes. The method includes coupling a removably coupleable frame to a refrigerated cold plate to define an enclosure for receiving a fluid, freezing the fluid in the enclosure into a slab of ice, transferring the slab of ice to a cutting unit having heated electrical wires, and dividing the slab of ice into ice cubes using the heated electrical wires.

In yet another aspect, the disclosure provides a method for producing craft ice including forming an enclosure around a refrigerated cold plate, filling the enclosure with water, stirring the water while the refrigerated cold plate freezes the water into an ice block, transferring the ice block to a cutting unit, cutting the ice block into ice cubes with heated wires, providing a tray with shallow dividers below the heated wires to receive ice cubes, and refreezing the ice cubes on the tray.

In yet another aspect, the disclosure provides a method for producing craft ice including providing a temperature-controlled enclosure around a freezing unit for producing an ice block and a cutting unit for cutting the ice block into ice cubes, producing the ice block using the freezing unit in the temperature-controlled enclosure, and cutting the ice block using the cutting unit in the temperature-controlled enclosure.

In yet another aspect, the disclosure provides an apparatus for producing craft ice including a production assembly having one or more freezing units and one or more cutting units. The production assembly includes a temperature-controlled enclosure for controlling the ambient environment around the one or more freezing units and the one or more cutting units.

In some implementations, the production assembly includes a refrigerated storage space for storing ice cubes.

Before any implementations of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other implementations and of being practiced or of being carried out in various ways. The terms “substantially”, “generally”, and “about” may be used herein to encompass both “exactly” and “approximately.”

DETAILED DESCRIPTION

FIG.1illustrates a freezing unit10for freezing a block of ice12(which may be referred to herein as an ice block12and/or a slab of ice12and is illustrated inFIGS.5-7). The freezing unit10includes a cold plate14and a frame16removably coupleable to the cold plate14. In the illustrated implementation, the cold plate14and the frame16are coupleable selectively between a coupled state and an uncoupled state by way of a latch18, which may include any suitable fastener for selectively coupling and uncoupling the cold plate14and the frame16. In the coupled state, the cold plate14and the frame16are coupled and form an enclosure20, which is a hollow enclosed space capable of being filled with water. The cold plate14and the frame16may form a water-tight seal therebetween in the coupled state, e.g., by way of the frame16being mounted in compression against the cold plate14and/or having an elastomeric seal (not shown), or in any other suitable manner. In some implementations, the freezing unit10includes a frame lift22(illustrated schematically inFIG.9), such as a hydraulic lift, for automatically moving the frame16and/or the cold plate14between the coupled and uncoupled states.

A fluid source24, such as water or another fluid from a utility, a well, a holding tank, etc., is in fluid communication with the enclosure20by way of an inlet port26. For example, in the illustrated implementation, pressurized utility or well water passes through a filter28, such as a reverse osmosis filter, and is subsequently held in a storage tank30. The storage tank30provides filtered water to the enclosure20. The storage tank30may include a pressurized air bladder (not shown) for creating and/or maintaining a water supply pressure. The storage tank30may be disposed in a refrigerated space32, which may be incorporated into temperature-controlled enclosure114(as illustrated inFIGS.5-7and discussed in greater detail below), to pre-chill the filtered water and reduce freeze time of the freezing unit10. A fill valve31may be disposed in the line to the enclosure20to allow manual or electronic control of filling the enclosure20. In other implementations, the fluid source24may provide water directly to the enclosure20without a filtration system. In yet other implementations, the fluid source24may supply other fluids, such as juice, soda, infused water, flavored water, etc., and the fluid source24need not be pressurized.

The frame16includes a top34and a plurality of sidewalls36and is insulated to increase efficiency of freezing and inhibit cracking of ice. In the illustrated implementation, the top34and sidewalls36are generally orthogonal to each other. For example, in the illustrated implementation, the frame16includes four sidewalls36forming a generally rectangular shape that define sides of the slab of ice12formed on the cold plate14. However, in other implementations, the frame16may have other shapes and/or a different number of sidewalls36. The top34of the frame16may be formed as one piece with the sidewalls36or may be a separate piece, removably attachable to the sidewalls36. In some implementations, the top34may rest on top of the sidewalls36during operation. Each of the sidewalls36and the top34may include insulation, such as polystyrene foam, or another suitable insulating material. In some implementations, some of the sidewalls36and/or the top34may be uninsulated, in any combination.

An ice thickness sensor38, such as a linear actuator with a limit switch, may be coupled to the frame16, e.g., to the top34of the frame16. In the implementation in which the ice thickness sensor38includes a linear actuator, the linear actuator may be configured to extend downwards towards the cold plate14to measure a height (which may also be referred to herein as a thickness or an ice thickness) of the forming ice, as will be described in greater detail below. In other implementations, other types of ice thickness sensors may be employed. A temperature sensor40may be coupled to the frame16to measure a temperature of the water in the enclosure20, and a cold plate temperature sensor164may measure a temperature of the cold plate14.

A plurality of motors42are mounted to the top34of the frame16, each having a motor shaft44, each passing through the top34and into the enclosure20, and an impeller46mounted on each motor shaft44. Each impeller46is disposed within the enclosure20for stirring the fluid in the enclosure20, as will be described in greater detail below. As illustrated inFIG.2, the plurality of motors42includes three motors42mounted centrally and arranged in a generally linear fashion along a central longitudinal axis A of the top34, evenly spaced across the top34of the frame16, and mounted at uniform height (H) above the cold plate14. In other implementations, the plurality of motors42may be mounted to any side of the freezing unit10, the number of motors42may be two, four, or more in other implementations, and the arrangement of motors42may be linear, non-linear, staggered, grid-like, etc., mounted at the same height or different heights above the cold plate14. In yet other implementations, a single motor42may be employed.

The overall dimensions of the enclosure20are about 24 inches in length L, about 16 inches in width W, and about 8 inches in height H (+/−1 inch). The enclosure20dimensions are described herein as an inner dimension between inner surfaces of the freezing unit top34, sidewalls36, and cold plate14that define the enclosure20. In other implementations, any desired dimensions may be employed in order to produce ice of any desired size. For example, the dimensions of the enclosure20in other implementations may generally be about 8 to about 72 inches in length L, about 8 to about 60 inches in width W, and about 3 to about 12 inches in height H (+/−1 inch). In yet other implementations, the dimensions of the enclosure20may be about 12 to about 48 inches in length L, about 8 to about 32 inches in width W, and about 4 to about 8 inches in height H (+/−1 inch). More specifically, the dimensions of the enclosure20in other implementations may be about 26 inches in length L, about 18 inches in width W, and about 6 inches in height H (+/−1 inch). In other implementations, the dimensions of the enclosure20may be about 32 inches in length L, about 24 inches in width W, and about 6 inches in height H (+/−1 inch). In other implementations, the dimensions of the enclosure20may be about 48 inches in length L, about 32 inches in width W, and about 6 inches in height H (+/−1 inch). Generally, the enclosure20dimensions may be increased slightly above the desired dimensions of the cut ice cubes84to compensate for dimensional losses due to melting, e.g., during the cutting process. The number of motors42and/or size of the impellers46may be scaled up or down depending on the size of the enclosure20.

Each of the plurality of sidewalls36includes a heater48, such as a heated electrical wire, preferably disposed against the outer surface of the sidewalls36in direct communication with the enclosure20. The heater48is disposed at a bottom of the sidewalls36, directly adjacent the cold plate14, and is coiled in a serpentine fashion to a height of about 2 inches (+/−0.5 inches) in the illustrated implementation. In other implementations, the heater48may be disposed to any desired height. Generally, the heater48is configured to heat at least about one fourth of the height of the enclosure20, directly adjacent the cold plate14.

A pump50for pumping fluid out of the enclosure20is disposed in fluid communication with the enclosure20by way of an outlet port52. The outlet port52is in fluid communication with the fluid that remains above any ice formed in enclosure20. The pump50may be configured to direct the pumped fluid to a drain, a reservoir, or the like, and in other implementations the pump50may be configured to recycle the pumped fluid back to storage tank30or inlet port26. The operation of pump50and outlet port52may be combined with fill valve31and inlet port26such that filling and draining of enclosure20is performed with one port.

The cold plate14includes a generally planar heat exchange surface54disposed at a top of the cold plate14in direct communication with the enclosure20. The cold plate14may also include a generally planar bottom surface56generally parallel to the heat exchange surface54. One or both of the heat exchange surface54and the bottom surface56may be formed from a heat conductive material, such as metal—for example, aluminum, or any other suitable material. The aluminum may be anodized to inhibit formation of aluminum oxide. The cold plate14may also include a polycarbonate layer (not shown) disposed on the heat exchange surface54in direct communication with the enclosure20to better match an ice expansion coefficient and reduce ice adhesion to the heat exchange surface54. First and second heat exchanger coils58,60carrying a refrigerant run through the cold plate14in a serpentine fashion. The first and second heat exchanger coils58,60are interleaved and are disposed between the heat exchange surface54and the bottom surface56, e.g., sandwiched therebetween. The cold plate14may be insulated (e.g., below the bottom surface56of the cold plate14) with any suitable insulating material, such as polystyrene foam.

In the illustrated implementation, first and second heat exchanger coils58,60are disposed in the cold plate14. The cold plate14includes first and second inlets62,64in a first end70of the cold plate14and first and second outlets66,68in a second end72generally opposite the first end70. The first and second heat exchanger coils58,60are formed from tubes, such as copper tubes, and are configured in parallel to receive a flow of refrigerant flowing in the same direction. However, in other implementations, the first and second heat exchanger coils58,60may be configured to receive the flow of refrigerant in opposite directions such that the first inlet62and the second outlet68are disposed at the first end70, and the first outlet66and the second inlet64are disposed at the second end72. In other implementations, three, four, or more heat exchanger coils may be employed and may be arranged in any suitable configuration, e.g., for smaller spacing between coil runs and increased capacity. In yet other implementations, only a single heat exchanger coil need be employed.

The first and second heat exchanger coils58,60form part of a refrigeration system74, illustrated inFIG.3. The refrigeration system74generally includes a compressor76, the first and second heat exchanger coils58,60in parallel with each other, an expansion valve78, and a third heat exchanger coil80. The refrigeration system74may have a fixed capacity or a variable capacity. The refrigeration system74is reversible and may operate in a cooling mode and a heating mode, selectively. In the cooling mode, the first and second heat exchanger coils58,60serve as evaporator coils to cool the cold plate14and the third heat exchanger coil80serves as a condenser to reject heat from the system. In the heating mode, the first and second heat exchanger coils58,60serve as the condenser to heat the cold plate14and the third heat exchanger coil80serves as the evaporator to absorb heat from the environment. The reversibility may be achieved by reversing the compressor76to change the direction of fluid flow in the circuit or by including a switching valve166(illustrated schematically inFIG.9) and piping arrangement (not shown) to selectively direct compressed refrigerant from the compressor76to the third heat exchanger coil80when the switching valve166is in a first position (corresponding with the cooling mode) and to the first and second heat exchanger coils58,60when the switching valve166is in a second position (corresponding to the heating mode). Any other suitable arrangement for reversing the refrigeration system74may also be employed.

FIGS.4A-4Billustrate a cutting unit82for cutting the ice block12into ice cubes84and a tray86for separating the ice cubes84for storage. The term “ice cube” is used herein to refer to any shape of ice cut by the cutting unit82, including but not limited to a square cube, a rectangular cuboid, a parallelepiped, a stick or spear, a cylinder, or any other extruded shape with any combination of straight and/or curved edges, such as an extruded polygon, star, semi-circle, etc. The cutting unit82includes a plurality of heated wires88, such as heated electrical wires, tensioned on a cutting unit frame90and electrically coupled to a non-heated electrical wire92providing power to the plurality of heated wires88. In the illustrated implementation, the heated wires88are formed from stainless steel or another suitable metal or other material. The plurality of heated wires88may each be tensioned by way of a biasing member94, such as coil spring, such that the tension is adjustable individually, as illustrated. Each heated wire88includes spacers96and a sleeve98for insulating the heated wire88from the cutting unit frame90, which may be formed from acrylic or another suitable polymeric or plastic material. The spacers96and sleeve98may be formed from a high temperature insulating material. In other implementations, one or more of the heated wires88may be grouped together with one or more biasing members94to be tensioned and adjustable as a group, and the biasing member94may include other types of springs and tensioning elements, such as leaf springs and the like.

The cutting unit82, and more specifically the inner dimensions of the cutting unit frame90, generally has the same length L and width W as the enclosure20(+/−1 inch), or may be larger in one or both dimensions in other implementations. This allows the ice block12to fit in the cutting unit82, within the cutting unit frame90, and may provide some extra space to account for the ice block12melting during the cutting process, which will be described in greater detail below. The freezing unit10may also include an ice block ram100(illustrated schematically inFIG.9) for pushing the ice block12horizontally (e.g., in the lengthwise direction L) to move the ice block12from the freezing unit10to the cutting unit82. For example, the ice block ram100may include a hydraulic ram, an electrical linear actuator, or other suitable ram or sliding/pushing mechanism.

The plurality of heated wires88may be arranged in parallel in the lengthwise and widthwise dimensions L, W to form a grid, each of the heated wires88spaced from a directly adjacent one of the heated wires88by wire spacings D1and D2in each dimension, respectively, according to any desired size of ice cubes84, as illustrated. The heated wires88may also be spaced from each other in the height direction by a small gap, enough so that overlapping heated wires88in the grid do not touch each other. Furthermore, the cutting unit frame90may be formed from two separate pieces (not shown)—e.g., a first frame part for tensioning the lengthwise heated wires88and a second frame part for tensioning the widthwise heated wires88, with the first and second frame parts being stacked one on top of the other for operation, which also provides the small gap between the heated wires88in the height direction.

The cutting unit82may include a plurality of cutting unit frames90. The cutting unit frame90may be interchangeable with other of the plurality of cutting unit frames90which may have different wire spacings D1, D2to form different shapes and/or sizes of ice cubes84, and the heated wires88need not be parallel. In some implementations, the heated wires88may be formed rigidly into any shape, including straight and/or curved shapes. For example, the heated wires88may be arranged in a grid of about 2 inches (D1) by about 2 inches (D2) (+/−⅛ inch), as illustrated inFIG.4A, to form ice cubes84of corresponding dimension. Another (not shown) of the plurality of cutting unit frames90interchangeable therewith may have the heated wires88arranged in a grid of about 1.3 inches (D1) by about 4.8 inches (D2) (+/−⅛ inch) to form a spear-shaped ice cube of corresponding dimension. In other implementations, the heated wires88may be arranged to have other shapes, spacings, etc. for other desired ice cube shapes (for example, see the shapes listed above).

The tray86has overall dimensions W1, L1that are at least equal to the length L and width W of the enclosure20, and are slightly larger than the length L and the width W of the enclosure20in the illustrated implementation. The tray86includes a generally planar base surface102and a plurality of dividers104protruding from the base surface102. Walls105aof the plurality of dividers104extending in the direction of width W have a width X1(see enlarged view ofFIG.4B) and walls105bof the plurality of dividers104extending in the direction of length L have a width X2. In the illustrated implementation, the overall length L1and width W1of the tray86is increased over length L and width W of the enclosure20by the addition of all the widths X2in the direction of the length L1and all the widths X1in the direction of the width W1. The divider width X1, X2is sufficient to reduce the amount of melted fluid that remains between adjacent ice cube84surfaces without significantly increasing the dimensions of the tray86. For example, each divider104may increase the overall length L1and width W1of the tray86by 0.0625 inches to 0.5 inches. In other words, each of the divider widths X1, X2may be 0.0625 inches to 0.5 inches. For example, in the illustrated implementation the divider widths X2, X2are 0.0625 inches to 0.125 inches.

The plurality of dividers104define a plurality of shallow receptacles106, one receptacle106for each ice cube84cut by the cutting unit82. The plurality of dividers104are positioned to separate each ice cube84from each of the adjacent ice cubes. A divider height H1is sufficient to keep the ice cubes84in their corresponding receptacles106during the transportation of tray86to frozen storage (e.g., 0.0625 inches to 0.5 inches). This low profile of the dividers104inhibits the ice cubes84from sticking to the dividers104in frozen storage, as will be described in greater detail below. The tray86includes a plurality of apertures108(see enlarged view ofFIG.4B) through the base surface102for draining melted water away from the ice cubes84while the plurality of dividers104separate individual ice cubes84, thereby inhibiting sticking and clumping of the ice cubes84to each other and to the tray86. The plurality of apertures108may be disposed directly under the heated wires88, thereby being formed through the dividers104, as illustrated inFIGS.4A-4B. In other implementations, the apertures108may be formed anywhere in the tray86. There is generally at least one aperture108associated with each receptacle106, though there may be one or more than one aperture108per receptacle106in other implementations. The tray86may be manually or automatically moved into a freezer storage compartment122(e.g., see the implementation ofFIGS.5-7described below for automatic moving) without an operator having to directly handle the ice cubes84. During refreezing in the storage compartment122, the dividers104and apertures108help inhibit sticking and clumping of the ice cubes84to each other and inhibit the accumulation of fluid that would affect the shape of the ice cubes84when re-frozen. The dividers104also facilitate easy removal of the ice cubes84from the tray86.

FIGS.5-7illustrate one implementation of a production assembly110for producing and storing ice cubes84. The production assembly110includes two of the freezing units10illustrated inFIG.1(i.e., a first freezing unit10′ and a second freezing unit10″) and one of the cutting units82illustrated inFIG.4A(i.e., a cutting unit82′), each as described above. This arrangement may be referred to herein as a “dual freezing/cutting assembly”. Components of the production assembly110that are described individually above that are part of the production assembly110described below may be referenced herein using the same reference numerals as above and may additionally include a prime (“′”) for each iteration of the component. Reference is made to the above description for each component, and only additions, differences, and/or alternatives need be described below.

The cutting unit82′ is disposed centrally between the first and second freezing units10′,10″ such that the cutting unit82′ is configured to receive an ice block12alternatingly from each freezing unit10′,10″. The cutting unit82′ and the freezing units10′,10″ are supported on a generally planar support surface112. The cutting unit82′ may be configured as interchangeable modules with varying cutting dimensions such that the dimensions of ice cubes84are easily altered in the production assembly110. The cutting unit82′ and the freezing units10′,10″ may be enclosed by a temperature-controlled enclosure114. The temperature-controlled enclosure114provides a more consistent environment for the freezing units10′,10″ and the cutting unit82′ to produce and cut ice, shielded from fluctuations of the broader environment, thereby improving ice production consistency and reliability. In other implementations, the production assembly110may include any number of freezing units10and cutting units82, such as three freezing units and one cutting unit, four freezing units and two cutting units, etc., in any number and combination. Further examples will be described in greater detail below.

The first and second freezing units10′,10″ are cooled by a single compressor76, such as the compressor76shown inFIG.3and discussed above. Thus, the refrigeration system74for the production assembly110would include modifications relative toFIG.3such that the circuit includes another set of heat exchanger coils (i.e., fourth and fifth heat exchanger coils, not shown, for the second cold plate14″) in parallel with the first and second heat exchanger coils58,60shown. The refrigeration system74′ for the production assembly110may also include a control valve120(shown schematically inFIG.9) for controlling the ratio of refrigerant flowing to the first and second heat exchanger coils58,60versus to the fourth and fifth heat exchanger coils so as to control the distribution of refrigeration capacity between the first and second freezing units10′,10″. The ratio may be adjustable so that as an ice thickness in the first freezing unit10′ increases, a portion of the refrigeration capacity is switched to the second freezing unit10″ to begin ramping up the ice-production process in the second freezing unit10″ as the ice-production process in the first freezing unit10′ ramps down, as will be discussed in greater detail below with respect toFIG.8.

The production assembly110also includes a storage compartment122for storing the trays86of ice cubes84in a stacked fashion. The storage compartment122is configured to receive first and second stacks124,126of trays86in the illustrated implementation—for example, one stack for each freezing unit10, though any number of stacks may be employed in other implementations. The storage compartment122is disposed generally below the support surface112. The support surface112includes an opening128from the temperature-controlled enclosure114to the storage compartment122, and the cutting unit82′ is disposed generally in, on, or near the opening128such that the ice that is cut by the cutting unit82′ drops through the opening128into one of the trays86disposed in a receiving location130in the storage compartment122below. In other implementations, the tray86may be above the opening128and the tray86may be lowered into the storage compartment122.

The temperature-controlled enclosure114and the storage compartment122may be cooled by a second refrigeration system having the components shown inFIG.3and described above. The second refrigeration system may drive separate temperatures in the temperature-controlled enclosure114and the storage compartment122with a single compressor, e.g., in a manner similar to a conventional combined refrigerator/freezer unit. In other implementations, the temperature-controlled enclosure114and the storage compartment122may be controlled by independent refrigeration systems. In yet other implementations, other configurations may be employed.

A conveyor system132may be disposed in the storage compartment122, as illustrated schematically inFIGS.5-7. The conveyor system132is configured to move an empty one of the trays86to the receiving location130for receiving ice cubes84from the cutting unit82′. Then, when the ice cubes84are received and the tray86is loaded, the conveyor system132is configured to move the loaded tray86to a storage location134within one of the first or second stacks124,126in the storage compartment122. The conveyor system132may be configured to alternatingly select empty trays86from one of the first or second stacks124,126, and return each tray86, once loaded, to its original storage location134. In other implementations, the conveyor system132may be configured to select empty trays86from one of the first or second stacks124,126until the respective stack124,126is fully loaded and then switch to the other of the first or second stacks124,126for loading. Each stack124,126may include four or more trays86stacked generally vertically, as illustrated, though any number of trays86may be in a stack in other implementations.

FIG.8illustrates a dual freezing cycle136of the production assembly110having the first and second freezing units10′,10″ alternatingly supplying ice blocks12to a single cutting unit82′ (i.e., the dual freezing/cutting assembly). In this arrangement, a controller140is configured to control the refrigeration system74′ (e.g., by way of the control valve120) to allocate varying ratios of the refrigerant to the first freezing unit10′ (and more specifically to the first cold plate14′ which may also be referred to herein as “plate A” for simplicity) and the second freezing unit10″ (and more specifically to the second cold plate14″ which may also be referred to herein as “plate B” for simplicity).FIG.8illustrates, over time, the temperature of plate A in degrees Fahrenheit (“PLATE A (F)”), the temperature of water above plate A in degrees Fahrenheit (“WATER A (F)”), the cooling power allocated to plate A in calories/second (“COOLING A”), the temperature of plate B in degrees Fahrenheit (“PLATE B (F)”), the temperature of water above plate B in degrees Fahrenheit (“WATER B (F)”), the cooling power allocated to plate B in calories/second (“COOLING B”), the thickness of ice over plate A in inches on the right vertical axis (“ICE A (IN)”), and the thickness of ice over plate B in inches on the right vertical axis (“ICE B (IN)”).

As illustrated inFIG.8, the dual freezing cycle136begins with 100% of the cooling capacity allocated to plate A, which begins to pull down the temperature of the water on plate A. After a period of pulldown time (e.g., about 94 minutes in this example), the water on plate A reaches a freezing point (32 degrees Fahrenheit) and a layer of ice begins to form on plate A. A thickness of the ice increases over a time period (e.g., about 40 minutes in this example) during which the cooling capacity remains at 100% with plate A. The time period may be preset as a time (e.g., based on a timer) or a preset ice thickness (programmed to a first thickness threshold based on a measurement from the thickness sensor38) that triggers switching to a capacity-sharing mode. In response to the trigger, the controller140is in the capacity-sharing mode and begins to allocate a portion of the cooling capacity to plate B and gradually increases cooling capacity to plate B while decreasing cooling capacity to plate A. After a set period of ramping down cooling capacity to plate A and ramping up cooling capacity to plate B (e.g., about 100 minutes in this example, which may be determined by presetting the timer to a desired duration or by the thickness sensor38and setting a second desired thickness threshold) the cooling capacity is 50% to plate A and 50% to plate B, and the cooling capacity thereafter continues to increase to plate B and decrease to plate A. Even during the period of time that the cooling capacity to plate B is higher than the cooling capacity to plate A (e.g., from about 194 minutes on the x-axis ofFIG.8to about 312 minutes on the x-axis ofFIG.8), plate A continues to generate increasing ice thickness while plate B is prepped for its freezing cycle and begins pulling down the temperature of water on plate B. Once the ice on plate A reaches a desired thickness (e.g., about 2 inches for cubes, about 4.8 inches for spears, etc., which may be determined by presetting a third desired thickness threshold), then 100% of the cooling capacity is allocated to plate B so plate A is deactivated (i.e., cooling capacity is zero to plate A such that plate A is turned off). The cycle then continues as described above but with plate B as the primary cold plate instead of plate A, and then the cycle repeats again with plate A as the primary cold plate as described above. If the timer is used to preset a time or duration for any given portion of the cycle described above, then it should be understood that “about” is used above with respect to a number of minutes with a margin of +/−10 minutes and that the preset times may be set to any desired duration in other implementations to achieve the desired results. The dual design more efficiently utilizes compressor cooling capacity and lowers on/off cycling of the compressor76, thereby extending the life of the compressor76.

In other implementations, the production assembly110may employ other arrangements of freezing units10and cutting units82. For example, a single cutting unit82may be dedicated for every freezing unit10(which may be referred to herein as a “dedicated freezing/cutting assembly”). As another example, multiple freezing units10may supply ice blocks12to a single cutting unit82(which may be referred to herein generally as a “shared freezing/cutting assembly” or an “assembly line”). The multiple freezing units10may be synchronized such that the timing of each ice block release is spaced and driven by the cutting unit82capacity. Any of these arrangements may be employed individually and in other implementations may be duplicated within the production assembly110, e.g., more than one dedicated freezing/cutting assemblies may be disposed in the temperature-controlled enclosure114, more than one of the dual freezing/cutting assemblies may be disposed in the temperature-controlled enclosure114, more than one of the shared freezing/cutting assemblies may be disposed in the temperature-controlled enclosure114, or any other combination of said freezing/cutting assemblies, etc. Also, in other implementations, any combination of one or more freezing units10and one or more cutting units82may be operated individually and manually, or in any combination of manually and automatically, with or without being configured into the production assembly110.

As illustrated inFIG.9, the controller140includes a programmable processor142(e.g., a microprocessor, a microcontroller, or another suitable programmable device), a memory144, and a human-machine interface146(seeFIGS.5-7). The memory144may include, for example, a program storage area148and a data storage area150. The program storage area148and the data storage area150can include combinations of different types of memory, such as read-only memory (“ROM”), random access memory (“RAM”) (e.g., dynamic RAM [“DRAM”], synchronous DRAM [“SDRAM”], etc.), electrically erasable programmable read-only memory (“EEPROM”), flash memory, a hard disk, an SD card, or other suitable magnetic, optical, physical, electronic memory devices, or other data structures. The controller140may also, or alternatively, include integrated circuits and/or analog devices, e.g., transistors, comparators, operational amplifiers, etc., to execute the logic and control signals described herein.

The human-machine interface146includes a display panel152and a control panel154. The display panel152may display information regarding temperature and setpoint of the temperature-controlled enclosure114, temperature and setpoint of the first and second cold plates14′,14″, an operation state (e.g., the mode) of the refrigeration system74and/or the capacity allocation to the first and second cold plates14′,14″, an operation state of the motors42, an operation state of the heaters48, water temperature, cold plate temperature, an operation state of the cutting unit82,82′, the timer, an indicator representative of the number of loaded trays86or the amount of ice in the storage compartment122, etc.

The controller140includes a plurality of inputs156and outputs158to and from various components, as illustrated inFIG.9. The controller140is configured to provide control signals to the outputs158and to receive data and/or signals (e.g., sensor data, user input signals, etc.) from the inputs156. The inputs156may include, but are not limited to, the control panel154, a fluid level sensor162, the water temperature sensor40, the cold plate temperature sensor164(and other temperature sensors to any other component described herein), the thickness sensor38, and a digital data storage device168, and may include other components described herein. The outputs158may include, but are not limited to, the impeller motors42, the pump50, the refrigeration system74(e.g., the compressor76, the control valve120, the switching valve166), the fill valve31, the heater48, the heated wires88, the conveyor system132, the latch18, the frame lift22, the ice block ram100, the display panel152, and the linear actuator38, and an engraving tool170, and may include other components described herein. Thus, the controller140may be programmed to automatically control any of these components, as will be described in greater detail below.

The control panel154may include a plurality of control actuators160(seeFIGS.5-7), such as buttons including mechanical, capacitive touch, resistive, etc., as well as knobs, dials, etc. in any combination, for providing an input control signal to the controller140to control any of the components of the production assembly110, such as those shown inFIG.9.

The inputs156and outputs158are in communication with the controller140, e.g., by way of hard-wired or wireless communications such as by satellite, internet, mobile telecommunications technology, a frequency, a wavelength, Bluetooth®, or the like.

In operation, the controller140may be configured to automatically fill the enclosure20(in a fill mode) to a desired height for the desired size of ice cube, e.g., by way of the fluid level sensor162in communication with the controller140and a feedback control loop with the fill valve31. The desired height is preferably higher than the desired ice cube height in order to allow continued stirring of the fluid during the freezing process as the fluid freezes. For example, the desired ice cube height is at least 1 inch and the desired height is at least 2 inches to allow continued stirring as the ice slab forms to the height of 1 inch. In other examples, the desired ice cube height is at least 1.5 inches and the desired height is at least 2.5 inches. In yet other examples, the desired ice cube height is at least 2 inches and the desired height is at least 3 inches. In yet other examples, the desired ice cube height is more than 2 inches (such as at least 2.5 inches, at least 3 inches, at least 3.5 inches, at least 4 inches, at least 4.5 inches, at least 5 inches, etc.). The fluid freezes starting at the cold plate14in thin layers extending away from the cold plate14as the water is stirred by the impellers46. In other implementations, the enclosure20may be manually filled by an operator to the desired height.

The controller140may be configured to control the refrigeration system74to cool the cold plate14,14′,14″ to produce ice. In other implementations, the refrigeration system74may be manually operated. For example, the cold plate14may be set to an initial setpoint for cooling and freezing water in the enclosure20, and then the setpoint may be lowered as ice thickness increases to a desired height. The thicker the ice, the larger the temperature difference may be between the 32-degree water above the ice and the cold plate14below. As such, lowering of the setpoint as the ice thickens may facilitate further freezing. Then, the setpoint may be increased slowly with either the compressor76being off or running only occasionally to slow the rate of temperature increase to inhibit cracking of the ice. The temperature of the cold plate may be raised further by reversing the refrigeration system74to use the compressor's hot gas. The setpoint may be adjusted (e.g., as described above) either manually or automatically based on water temperature measured by the temperature sensor40, based on ice thickness measured by the thickness sensor38, and/or based on time.

For the dual first and second cold plates14′,14″, the controller140may be configured to control the refrigeration system74as described above with respect toFIG.8.

The controller140may be configured to activate the impellers46during ice formation to continuously stir the water above the ice. Constant water movement over the forming ice facilitates the production of clear ice. The linear arrangement of impellers46inhibits turbulence at the top surface of the forming ice to facilitate a smoother and more planar top surface of the ice.

The controller140may be configured to periodically or continuously monitor ice thickness, e.g., by way of the thickness sensor38, and adjust control of the refrigeration system74(e.g., to increase or decrease the setpoint temperature, the capacity allocation, to reverse the cold plate14to heating mode, etc.) based on the sensed ice thickness (e.g., based on the actual measured thickness or on the measured thickness as a percentage of the desired ice thickness, for example). For example, seeFIG.8described above. The refrigeration system74may also be controlled manually in other implementations, e.g., by way of the control panel154.

The controller140may be configured to activate the pump50to remove excess water from the enclosure20when the desired ice thickness is reached, as sensed by the thickness sensor38. In other implementations, the pump50may be activated manually, e.g., by way of the control panel154.

The controller140may also be configured to activate the heater48to facilitate removal of the ice block12from the enclosure20in conjunction with the cold plate14being in the heating mode using compressor hot gas. The heating mode may be timed to inhibit cracking of the ice. The insulation in the frame16may also inhibit cracking of the ice by slowing the rate of temperature change in the ice. In some implementations, the heater48may be activated manually by the operator, e.g., by way of the control panel154. When the ice block12is not frozen to the frame16or the cold plate14, the controller140may be configured to automatically unlatch the frame16, to activate the frame lift22to move the frame16to the uncoupled state, and to move the ice block12to the cutting unit82by activating the ice block ram100. In some implementations, the frame lift22and the ice block ram100may be integrated into a single lift/ram device. In some implementations, the frame16and ice block12may be unlatched and lifted to the uncoupled state and moved manually by the operator.

Prior to the ice block12being cut by the cutting unit82, the engraving tool170(shown schematically inFIG.9), such as a computer numerical control (CNC) router, may be used to engrave a surface of the ice block12. For example, the engraving tool170may be mounted above the cutting unit82and configured to engrave the top surface of the ice block12. In other implementations, the engraving tool170may be mounted above the cold plate14, or above an intermediate location between the cold plate14and the cutting unit82. In other implementations, the engraving tool170may be disposed in other locations with respect to the ice block12, and other surfaces (such as a bottom surface and/or side surfaces) of the ice block12may be engraved.

The engraving may include indicia (e.g., graphics, logos, and/or text) repeated across the top surface of the ice block12and positioned such that one or more of the ice cubes84contain such indicia after the ice block12is cut. For example, the indicia may be placed approximately centrally in a location on the top surface of the ice block12corresponding to an ice cube84and repeated for every location on the top surface of the ice block12corresponding to an ice cube84. The indicia need not be engraved for every ice cube84, i.e, the indicia may be engraved on a portion of the ice block12. The indicia may be the same or different in each location on the top surface of the ice block12, and may be grouped into any number of different groups of repeating indicia.

The digital data storage device168(e.g., a computer, a personal computer, a laptop, a hard drive disk, a disc such as a compact disc (CD), a digital versatile disc (DVD), Blu-ray disc, or the like, a USB flash drive, a secure digital card (SD card), a solid state drive (SSD), cloud storage, etc.), shown schematically inFIG.9, may include a set of engraving instructions for the entire ice block12, or a portion thereof. The set of engraving instructions may be saved into a memory in the digital data storage device168(e.g., see the description of the memory144above). The digital data storage device168may be operably coupled to the controller140directly or through the control panel154. The digital data storage device168may communicate with the controller140and/or the control panel154by wired or wireless communications as described above. The controller140may then control the operation of the engraving unit170to execute the engraving instructions, e.g., once the ice block12is moved to the cutting unit82or other desired location.

The controller140may be configured to activate the heated wires88in the cutting unit82to cut the ice block12into ice cubes84. In some implementations, the heated wires88may be activated manually, e.g., by way of the control panel154. The ice block12slowly melts through the heated wires88under the effect of gravity to form ice cubes84which drop through the cutting unit82′ into the tray86below. The dividers104facilitate separation of the ice cubes84, while the apertures108in the tray86allow melted fluid to drop away from the ice cubes84, thereby inhibiting sticking and clumping of ice cubes84to each other when the tray86of ice cubes84is refrozen, e.g., in the storage compartment122.

The controller140may be configured to activate the conveyor system132to move the tray86loaded with ice cubes84to a storage position (FIG.6) and to move an empty tray86to a receiving position underneath the cutting unit82′ for receiving the next batch of ice cubes84.

In some implementations, the controller140may monitor ice production for auditing purposes. For example, data from the production assembly110regarding the number of freeze cycles of each cold plate14, cutting cycles of the cutting unit82, calculated quantity of ice produced, quantity of ice stored, quantity of ice removed from the storage compartment122, etc., may be stored in the memory144and capable of transfer or upload by wired or wireless connection, e.g., to the digital data storage device168or another similar device. (Thus, the digital data storage device168may also be an output158.) The data may be useful for monitoring production, auditing, process improvement, etc.

Thus, the disclosure provides, among other things, a method and apparatus for producing clear ice cubes. Although the disclosure has been described in detail with reference to certain preferred implementations, variations and modifications exist within the scope and spirit of one or more independent aspects of the disclosure as described.