Abstract:
An ice barrier and an ice making machine having an ice barrier is provided in some embodiments, wherein the ice barrier is movable between a first orientation in which liquid water from an ice-forming surface is directed into the liquid receptacle, and a second orientation in which the ice barrier blocks access of ice from the ice-forming surface to locations in which ice is trapped between the ice barrier and an adjacent surface. Also, a method of producing ice in an ice making machine is provided in some embodiments, wherein a barrier diverts a flow of liquid water received from the ice-forming surface away from an ice collection bin, and wherein the barrier is moved to an orientation in which the barrier diverts ice toward the ice collection bin and also blocks access of ice to positions trapped between the barrier and an adjacent surface.

Description:
BACKGROUND 
       [0001]    Many automated ice making machines have moving parts used to direct water and ice moving within the ice making machine. In many cases, these moving parts can become jammed by ice trapped by and/or within such moving parts. Resulting service calls for clearing jammed parts of trapped ice lead to unnecessary expense and maintenance of ice making machines. Also, one or more sensors often used to control operation of ice making machines based upon the position of a movable ice making machine part can produce false signals or can fail to produce necessary signals for proper machine operation. As a result, ice making machines can produce too much ice, can stop producing ice prematurely, or can malfunction in other manners. Clearly, in light of these and other problems and issues arising with respect to existing ice making machines, new ice making machines and methods would be welcome in the art. 
       SUMMARY 
       [0002]    Some embodiments of the present invention provide an ice making apparatus comprising an ice-forming surface with a plurality of ice-forming locations for forming ice cubes as liquid water is run across the ice-forming surface; an ice collection bin positioned at a lower elevation than the ice-forming surface; a liquid receptacle at a lower elevation than the ice-forming surface and positioned to collect liquid water from the ice-forming surface; and an ice barrier adjacent the liquid receptacle, the ice barrier movable between a first orientation in which liquid water from the ice-forming surface is directed into the liquid receptacle, and a second orientation in which the ice barrier blocks access of ice from the ice-forming surface to locations in which the ice is trapped between the ice barrier and an adjacent surface. 
         [0003]    In some embodiment, the present invention provides a barrier movable between a first orientation and a second orientation within an ice making apparatus having an ice collection bin, the barrier comprising a first surface for directing ice into the ice collection bin when the barrier is in the first orientation, and for directing liquid water away from the ice collection bin when the barrier is in the second orientation; and a second surface positioned with respect to the first surface to block movement of ice produced by the ice making apparatus into a trapped position between the barrier and another portion of the ice making apparatus when the barrier is in the first orientation. 
         [0004]    Some embodiments of the present invention provide a method of producing ice in an ice making machine, the method comprising running liquid water over an ice-forming surface; chilling the ice-forming surface to freeze at least a portion of the liquid water running over the ice-forming surface; orienting a barrier in a first orientation; diverting a flow of liquid water received from the ice-forming surface with the barrier away from an ice collection bin in which ice produced by the ice making machine is collected; moving the barrier to a second orientation; and directing ice received from the ice-forming surface toward the ice collection bin with the barrier in the second orientation while also blocking access of ice to positions trapped between the barrier and an adjacent surface with the barrier in the second orientation. 
         [0005]    Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a perspective view of an ice making machine according to an embodiment of the present invention; 
           [0007]      FIG. 2  is a perspective view of an evaporator assembly of the ice making machine of  FIG. 1 , shown with the ice barrier of the ice making machine in a first orientation; 
           [0008]      FIG. 3  is a perspective view of the evaporator assembly of  FIG. 2 , shown with the ice barrier in a second orientation; 
           [0009]      FIG. 4  is a perspective view of the ice barrier of  FIGS. 1-3 ; and 
           [0010]      FIG. 5  is a cross-sectional view of the ice barrier of  FIGS. 1-3 , taken along line  5 - 5  of  FIG. 4 . 
       
    
    
       [0011]    Before any embodiments of the present invention are explained in detail, it is to be understood that the invention 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 invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. 
       DETAILED DESCRIPTION 
       [0012]    An ice making machine  20  according to an embodiment of the present invention is shown in  FIG. 1 , and includes a pair of evaporator assemblies  24 , a water pump  28 , a water sump  32 , and an ice chute  36  through which ice pieces  38  are discharged to a bin (not shown) for collection and storage. Although the ice making machine  20  illustrated in  FIG. 1  is adapted for forming unconnected pillow-shaped pieces of ice, it should be noted that the various aspects of the present invention can be applied to ice machines adapted to produce ice in any other shape (e.g., cubes) formed in unconnected or connected assemblies on any type of ice forming surface (e.g., individual pockets or other receptacles, one or more troughs, a flat or substantially flat ice forming sheet, and the like). With reference again to the embodiment of  FIG. 1 , each evaporator assembly  24  of the illustrated ice making machine  20  includes an ice-forming surface  40 . 
         [0013]    Each evaporator assembly  24  in the illustrated embodiment has a shield  44  adjacent the ice-forming surface  40 . Although not required, the shield  44  can be used to control the discharge of ice from the ice-forming surface  40  during a harvesting cycle of the ice making machine  20 . The ice-forming surface  40  and the shield  44  are oriented substantially vertically and are spaced a relatively small distance apart, although it will be appreciated that the ice-forming surface  40  and/or the shield  44  can be oriented in other manners while still performing their respective functions. 
         [0014]    In some embodiments, a flexible curtain  46  can be attached to the shield  44  and can extend from a bottom portion of the shield. For example, each evaporator assembly  24  in the illustrated embodiment has a flexible curtain  46  attached to the shield  44 . The flexible curtain  46  is angled or curved toward the ice-forming surface  40  in an at-rest state, but is pliable and easily deflected outwardly away from the ice-forming surface  40  when contacted by ice pieces  38 . In other embodiments, the flexible curtain can have other shapes also capable of being deflected when contacted by ice falling from the ice-forming surface  40 . 
         [0015]    With continued reference to the illustrated embodiment, the shield  44  of each evaporator assembly  24  is supported by side panels  47  of the evaporator assembly  24  (see  FIGS. 2 and 3 ). In particular, the shield  44  has projections that mate with apertures in the side panels  47  of the evaporator assembly  24 . The shield  44  can be removable without the use of tools, such as by lifting the shield  44  from its position shown in  FIGS. 1-3 . In other embodiments, the shield  44  can be removably attached to the side panels  47  of each evaporator assembly in other manners, such as by projections of the side panels  47  removably received within apertures in the shield  44 , by pin and aperture connections, by other inter-engaging element connections, or in any other suitable manner. 
         [0016]    An evaporator  48  is connected to each ice-forming surface  40  of the illustrated ice making machine  20  in order to chill the ice-forming surfaces  40 . The evaporators  48  are part of a refrigeration system, which circulates a refrigerant through a refrigeration cycle to chill each ice-forming surface  40 . 
         [0017]    As shown in  FIG. 1 , the ice chute  36  is positioned between the evaporator assemblies  24  to receive ice pieces  38  therefrom. One evaporator assembly  24  is positioned adjacent the water pump  28  (near a first end  51  of the ice making machine  20 ), and the other evaporator assembly  24  is substantially remote from the water pump  28  (near a second end  52  of the ice making machine  20 ). The water sump  32  includes portions adjacent the first and second ends  51  and  52  of the ice making machine  20  to receive water from the adjacent evaporator assemblies  24  as described in further detail below. The water sump  32  extends around both sides of the ice chute  36  such that the portion of the water sump  32  adjacent the second end  52  of the ice making machine  20  is in communication with the portion of the water sump  32  adjacent the first end  51 . The water pump  28  is in fluid communication with the water sump  32  at the first end  51  of the ice making machine  20 . In other embodiments, water can be received within a water sump  32  having any other shape and size desired, such as a pan located generally beneath one or more evaporator assemblies  24 , one or more troughs positioned to receive water from one or more evaporator assemblies  24 , and the like. 
         [0018]    Unless otherwise noted, the description of the evaporator assembly  24  (and its components) herein applies to both evaporator assemblies  24 , which are substantially identical in structure and operation in the illustrated embodiment. Any number of evaporator assemblies  24  can be provided as part of the ice making machine  20 , such as one, three, or more evaporator assemblies  24 .  FIGS. 2 and 3  illustrate a single evaporator assembly  24  with the rest of the ice making machine  20  omitted for clarity. 
         [0019]    As shown in  FIG. 1 , an ice barrier  52  is positioned at the bottom of the evaporator assembly  24  along a boundary wall  54  separating the water sump  32  and the ice chute  36 . The ice barrier  52  of the illustrated embodiment is positioned vertically above the water sump  32  and the ice chute  36 , but substantially below the ice-forming surface  40 . The ice barrier  52  is rotatably mounted, and is movable about a pivot axis A between a first orientation (shown in  FIG. 2 ) and a second orientation (shown in  FIG. 3 ). In some embodiments, the ice barrier  52  is rotatably mounted to the evaporator assembly  24 , while in others the ice barrier  52  is also or instead rotatably mounted to other structure of the ice making machine  20 . 
         [0020]    In the first orientation shown in  FIG. 2 , the ice barrier  52  allows fluid communication between the ice-forming surface  40  and the water sump  32 . Unfrozen water flowing from the ice forming surface  40  is directed by the ice barrier  52  toward the water sump  32  in the first orientation of the ice barrier  52 . In the second orientation, the ice barrier  52  directs ice pieces  38  from the ice-forming surface  40  to the ice chute  36  and substantially blocks off the path of ice to the water sump  32 . 
         [0021]    Shown in detail in  FIGS. 4 and 5 , the illustrated ice barrier  52  includes first and second end portions  52 A and  52 B and a first portion  52 C extending between the first and second end portions  52 A and  52 B. The ice barrier  52  also includes a convoluted portion  52 D and a counterweight portion  52 E. The convoluted portion  52 D meets the counterweight portion  52 E at a second portion  52 F of the ice barrier  52 . The convoluted portion  52 D is formed to include a series of channels  56  spaced apart by a series of ridges  60 , and can be defined by a convoluted or corrugated shape. The channels  56  are concave to collect and direct water along the ice barrier  52  (substantially perpendicular to the pivot axis A) and into the water sump  32  in the first orientation of the ice barrier  52  described above. Each ridge  60  is convex to direct water into the adjacent channel(s)  56 . Water incident on the ice barrier  52  when in the first orientation shown in  FIG. 2  is directed toward the water sump  32  along a series of defined flow paths (i.e., the channels  56 ). Although the semi-circular or rounded channels  56  and ridges  60  of the convoluted portion  52 D have been found to perform in a superior manner in many cases, alternate profile shapes are considered, such as a V-shape for the channels  56  and/or ridges  60 . In still other embodiments, the first portion  52 C of the ice barrier  52  can be provided with ribs, bumps, or other protuberances, and/or grooves, holes, dimples or other recesses for directing water into a series of defined flow paths. Alternatively, the first portion  52 C can be substantially flat with no such features. 
         [0022]    Referring still to  FIGS. 4 and 5 , the counterweight portion  52 E of the ice barrier  52  includes a counterweight  68 . The counterweight  68  can take any shape, and can be defined by a single element or multiple elements. In the illustrated embodiment, for example, the counterweight  68  is substantially cylindrical. The counterweight  68  in the illustrated embodiment is positioned within a receiving channel  70 , which is covered by a cover  72  secured to the open end of the receiving channel  70 . In some embodiments, the cover  72  retains the counterweight  68  and/or seals off the receiving channel  70  from water within the ice making machine  20 . In other embodiments, the counterweight  68  can be integrally formed with the ice barrier  52  (e.g., molded or cast into the material of the ice barrier  52 ), can be slidably received in an elongated aperture at an end  52 A and/or  52 B of the ice barrier  52 , or can be attached to the ice barrier  52  in any other manner. The counterweight  68  has a position and weight, which act to bias the ice barrier  52  toward the first orientation, but to allow the ice barrier  52  to be pivoted toward the second orientation when ice pieces  38  fall onto the first portion  52 C. The biasing force (toward the first orientation) is affected by the material properties of the ice barrier  52  and the counterweight  68 , the location of the counterweight  68  with respect to the pivot axis A, and the shape and size of the ice barrier  52  relative to the pivot axis A. 
         [0023]    Although a counterweight  68  is used in the illustrated embodiment to bias the ice barrier  52  toward the first orientation illustrated in  FIG. 2 , other devices can be used to perform this function. For example, the ice barrier  52  can be biased by one or more springs (including without limitation torsion springs, coil spring, elastic bands, and the like), magnets, actuators (e.g., solenoids), drives connected to an axle at the pivot axis A or to suitable gearing connected to the ice barrier  52 , and the like. 
         [0024]    The ice barrier  52  includes two pivot pins  64  (one at each of the end portions  52 A and  52 B) which are received into the side panels  47  of the evaporator assembly  24 . Alternatively, pivot pins on the side panels  47  or other portion of the ice making machine  20  can be received within apertures in the ice barrier  52 . In this manner, the ice barrier  52  is capable of pivoting about the axis A. 
         [0025]    With reference now to  FIG. 4  of the illustrated embodiment, a magnet  76  is carried with the ice barrier  52  at its first end portion  52 A. The magnet  76  is positioned on the ice barrier  52  so that it is in close proximity to a switch  80  on the side panel  47  adjacent the first end portion  52 A when the ice barrier  52  is in the first orientation (see  FIGS. 2 and 3 ). When the ice barrier  52  is pivoted substantially away from the first orientation (i.e., toward the second orientation of  FIG. 3 ), the magnet  76  is substantially spaced apart from the switch  80 . The switch  80  senses the presence/absence of the magnet  76 , and controls the operation (e.g., on or off mode) of the ice making machine  20  based at least in part upon the orientation of the ice barrier  52 . Generally, the ice making machine  20  is on when the ice barrier  52  is in the first orientation, and is turned off by the switch  80  when the ice barrier  52  is in the second orientation. In some embodiments, the switch  80  includes a Hall-effect sensor to detect the presence or absence of the magnet  76 . The switch  80  in the illustrated embodiment is configured to interrupt the ice-making ability of the ice making machine  20  by stopping the water flow over the ice-forming surface  40  (driven by the water pump  28 ) and/or by stopping the refrigeration cycle that chills the ice-forming surface  40 . For this purpose, the switch  80  may be coupled to a controller (not shown) in communication with the water pump  28  and/or the refrigeration cycle. 
         [0026]    Although a magnet and magnetic field-sensitive sensor are used to detect the orientation of the ice barrier  52  in the illustrated embodiment, any other type of position and orientation-detecting devices can instead be used as desired. By way of example only, the orientation of the ice barrier  52  can be detected by one or more optical sensors, mechanical trip switches, rotary encoders, and the like. 
         [0027]    In operation, the ice making machine  20  produces ice pieces  38  by running water over the chilled ice-forming surface  40 . Water is drawn from the water sump  32  to the top of the evaporator assembly  24  by the water pump  28 . The water is discharged onto the ice-forming surface  40  from above. In other embodiments, water is supplied to the ice-forming surface  40  in other manners, such as by one or more sprayers positioned to direct water spray on the ice-forming surface  40 . In any case, water supplied to the ice-forming surface  40  runs down the ice-forming surface  40  by gravity. Some of the water incident on the ice-forming surface  40  freezes before reaching the bottom. The remainder of the water incident on the ice-forming surface  40  falls onto the first portion  52 C of the ice barrier  52 , which directs the water toward the water sump  32  for recirculation. Ice gradually builds up on the ice-forming surface  40 , forming an array of ice pieces  38 , which can be connected together in a sheet or can be individually formed and separate from each other. When an ice-making cycle (starting with no ice on the ice-forming surface  40  and ending with fully-formed ice pieces  38 ) is complete, the ice pieces  38  are released from the ice-forming surface  40 , from which they fall toward the ice barrier  52 . The ice pieces  38  deflect the flexible curtain  46  away from the ice-forming surface  40  and fall onto the first portion  52 C of the ice barrier  52 . The weight (and in some cases, also the falling force) of the ice pieces  38  causes the ice barrier  52  to pivot about axis A toward the second orientation shown in  FIG. 3 , overcoming the bias of the counterweight portion  52 E. Accordingly, the first portion  52 C of the ice barrier  52  functions as a lever arm for moving the ice barrier  52  from the first orientation toward the second orientation. 
         [0028]    By movement of the ice barrier  52  out of the first orientation and toward the second orientation, the ice pieces  38  are blocked from entering the water sump  32 , and instead are directed into the ice chute  36 . When the ice barrier  52  is in the second orientation, as shown in  FIG. 3 , the second portion  52 F of the ice barrier  52  abuts the evaporator  48 . The contact along the second portion  52 F not only prevents ice pieces  38  from entering the water sump  32 , but also closes a gap between the evaporator  48  and the ice barrier  52  to prevent ice pieces  38  from becoming lodged therebetween. 
         [0029]    The ice barrier  52  can remain in the second orientation while the ice pieces  38  are discharged from the ice-forming surface  40 . When the discharge of ice pieces  38  from the ice-forming surface  40  is complete, the ice barrier  52  returns to the first orientation, the flexible curtain  46  returns to the at-rest position, and a new ice-making cycle can be started. In some embodiments, the controller operates the evaporator assembly  24  in an “ice discharge mode” for a set amount of time before starting a new ice-making cycle (provided that the ice barrier  52  is in the first orientation, as sensed by the switch  80 ). The ice discharge mode can include stopping the refrigeration cycle, reducing the chilling effect of the refrigeration cycle, and/or reversing the flow of refrigerant in the refrigeration cycle to provide a heating effect to the evaporator  48  and the ice-forming surface  40 . However, any suitable method resulting in discharge of the ice pieces  38  from the ice-forming surface  40  is acceptable. 
         [0030]    In some embodiments, when the storage bin below the ice chute  36  becomes sufficiently full, the ice barrier  52  may not return to the first orientation from the second orientation at the end of an ice discharge event due to the piling of ice pieces  38  atop the first portion  52 D. For example, in the illustrated embodiment, the switch  80  remains open (signaling to the controller that the ice chute  36  is full), and a subsequent ice-making cycle is not started. This situation can occur when the rate of production by the ice making machine  20  exceeds the removal of ice from the storage bin. Thus, the switch  80  serves to prevent overfilling of the storage bin based on the orientation of the ice barrier  52 . 
         [0031]    With continued reference to the illustrated embodiment, after an ice discharge event is completed and/or when the ice chute  36  is emptied sufficiently to release the ice barrier  52  from the second orientation ( FIG. 3 ), the counterweight portion  52 E returns the ice barrier  52  to the first orientation ( FIG. 2 ). In order to avoid the opportunity for one or more ice pieces to become jammed in a gap between the ice barrier  52  and an adjacent surface (e.g., the adjacent evaporator assembly  24 , a frame element of the ice making machine  20 , or another adjacent part of the ice making machine  20 ), the ice barrier  52  is shaped to close the gap. In this context, jamming refers to a condition where one or more ice pieces  38  become lodged adjacent the ice barrier  52 . If an ice piece  38  is lodged between the ice barrier  52  and the adjacent structure, the switch  80  in the illustrated embodiment continues to indicate “bin full” indefinitely, even as the ice chute  36  is emptied. However, based upon the shape of the ice barrier  52  in the illustrated embodiment, the potential for jamming is essentially eliminated. 
         [0032]    More particularly, in some embodiments, the ice barrier  52  has two portions  52 C,  52 F that extend radially from the axis of rotation A of the ice barrier  52 . The two portions  52 C,  52 F can be contiguous as shown in  FIGS. 4 and 5 , or can be separated from one another by another element or a gap. The first and second portions  52 C,  52 F of the ice barrier  52  are oriented with respect to one another such that when the ice barrier  52  in the second orientation, the second portion  52 F of the ice barrier  52  abuts the evaporator  48  (or other adjacent structure) to prevent ice pieces  38  from being carried over into the water sump  32  or becoming lodged between the ice barrier  52  and the evaporator  48  (or other adjacent structure). When the ice barrier  52  is in the first orientation, a gap G is defined between the ice barrier  52  and the shield  44 . Specifically, the gap G is a width of unoccupied space between the convoluted portion  52 D and a bottom edge  88  of the flexible curtain  46  along the entire first portion  52 C of the ice barrier  52 . The gap G is at least as large as one of the ice pieces  38  (larger than its largest dimension if not a true cube). Therefore, even when an ice piece  38  is in a position to potentially jam the ice making machine  20  (e.g., on the ice barrier  52  when the ice barrier  52  is moving from the second orientation to the first orientation), the ice piece  38  cannot become lodged between the ice barrier  52  and the adjacent structure. The ice piece  38  falls off into the ice chute  36  before the counterweight portion  52 E moves the ice barrier  52  into the first orientation. The ice piece  38  does not interrupt the normal operation of the ice making machine  20  (as a lodged ice piece  38  could by inciting a false “bin full” signal from the switch  80 ). 
         [0033]    In an alternate embodiment, the ice making machine  20  includes a full-length pivotable water curtain in place of the shield  44  and flexible curtain  46 . The water curtain can be similar to that shown and described in U.S. Pat. No. 6,993,929 and/or U.S. Pat. No. 6,907,744, but need not necessarily have a contoured bottom edge to direct water into the water sump  32  (as the ice barrier  52  is configured to receive the water from the ice-forming surface  40 ). If used, the water curtain can be configured to swing out away from the ice-forming surface  40  when ice pieces  38  are discharged, allowing the ice pieces  38  to fall toward the ice chute  36 . Ice pieces  38  that fall on the ice barrier  52  can cause rotation of the ice barrier  52  from the first orientation to the second orientation. 
         [0034]    In the second orientation, the second portion  52 F of the ice barrier  52  abuts the evaporator  48  (or adjacent structure) to prevent ice pieces  38  from being carried over into the water sump  32  or becoming lodged between the ice barrier  52  and the evaporator  48  (or adjacent structure). In other embodiments, the second portion  32 F need not necessarily abut the evaporator  48  or other adjacent structure, and can instead be located sufficiently close to the evaporator  48  or other adjacent structure to prevent the ice pieces from entering into a jammed position therebetween. When the ice barrier  52  is in the first orientation, a gap is defined between the ice barrier  52  and the water curtain. The gap is a width of unoccupied space between the convoluted portion  52 D of the ice barrier  52  and a bottom edge of the water curtain along the entire first portion  52 C of the ice barrier  52 . The gap is at least as large as one of the ice pieces  38  (in its largest dimension if not a true cube). Therefore, even when an ice piece  38  is in a position to potentially jam the ice making machine  20  (e.g., on the ice barrier  52  when the ice barrier  52  is moving from the second orientation to the first orientation), the ice piece  38  cannot physically become lodged between the ice barrier  52  and the adjacent structure. The ice piece  38  falls off into the ice chute  36  before the ice barrier  52  reaches the first orientation. Thus, the normal operation of the ice making machine  20  is not easily interrupted by an ice piece  38 . 
         [0035]    The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present invention. As such, it will be appreciated by one having ordinary skill in the art that various changes in the elements and their configuration and arrangement are possible without departing from the spirit and scope of the present invention as set forth in the appended claims. Various features and advantages of the invention are set forth in the following claims. For example, although the ice making machine  20  illustrated in  FIG. 1  is shown as having two evaporator assemblies  24 , various aspects of the present invention disclosed herein can be utilized in ice making machines  20  have any other number of evaporator assemblies of the same or different type.