Patent ID: 12250954

DETAILED DESCRIPTION

The present disclosure extends to apparatuses, methods, and systems for freezing a liquid and conditioning ice in a form suitable for producing frozen confections. More specifically, the disclosure extends to forms for efficiently freezing water in a shape suitable for a frozen confection machine such that the ice is suitably strong for producing shaved ice. The features and advantages of the disclosure will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by the practice of the disclosure without undue experimentation. The features and advantages of the disclosure may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims.

For the purposes of promoting an understanding of the principles in accordance with the disclosure, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the disclosure as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the disclosure claimed.

Before the structure, systems and methods for producing ice are disclosed and described, it is to be understood that this disclosure is not limited to the particular structures, configurations, process steps, and materials disclosed herein as such structures, configurations, process steps, and materials may vary somewhat. It is also to be understood that the terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting since the scope of the disclosure will be limited only by the appended claims and equivalents thereof.

In describing and claiming the subject matter of the disclosure, the following terminology will be used in accordance with the definitions set out below.

It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

As used herein, the terms “comprising,” “including,” “containing,” “characterized by,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps.

As used herein, the phrase “consisting of” and grammatical equivalents thereof exclude any element or step not specified in the claim.

As used herein, the phrase “consisting essentially of” and grammatical equivalents thereof limit the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic or characteristics of the claimed disclosure.

Referring now to the figures,FIG.1illustrates an exploded perspective view of a form100for producing ice. The form100includes a structure component110and a base component120. The structure component110includes two structural sides112and a structural back114, each configured to surround a bag filled with a liquid. The base component120includes a base122and a side124. Each of the base122and the side124includes a lip126. The base component120is configured to slide into the structure component110such that the base122, side124, the structure sides112, and the back portion114form an enclosed space. The base122forms a base for the complete structure.

The form100is configured to hold a bag comprising a liquid for an extended period as the liquid is frozen. The sides112,114,124of the form comprise four sides surrounding the bag comprising a liquid. The sides and the base122form the structure of the frozen liquid.

In an implementation, the sides112,114have a height from about 15 inches to about 25 inches. In an implementation, the sides112,114have a height of 19 inches. In an implementation, the side of the base component has a height from about 15 inches to about 25 inches, and may particularly have a height of about 19 inches. In an implementation, the lip126extends out from either of the base122or the side124a distance from about 1 inch to about 2 inches, and may particularly extend a distance of about 1 1/16 inches. In an implementation, the base122is a square having a side length from about 5 inches to about 10 inches, and may particularly have a side length of about 6.5 inches. In an implementation, the base122is a rectangle.

In an implementation, the area formed by the sides112and back114of the structural component110is smaller than the area of the base122. In such an implementation, the structural component may slide into the base component120. The back114of the structural component110may be situated against the lip126attached to the base122.

FIG.2illustrates a generally front view of a form for producing ice. The form includes a structural back114attached to a structure component110. The form includes a side124attached to a base component120. The base component further includes two lips126, wherein one lip is attached to the side124and one lip is attached to the base122.

FIG.3illustrates an exploded side view of a form for producing ice. The form includes a base component120and a structural component110. As illustrated inFIG.3, the base component120and the structural component110may fit together such that the structural component and the base component form a five-sided structure. In an implementation, the five-sided structure is placed in a freezing compartment and a bag comprising a liquid is placed within the confines of the five-sided structure. The bag comprising a liquid may then conform to the five-sided structure such that the liquid freezes in a block form. The liquid may then be removed from the bag if desired.

FIG.4illustrates an exploded perspective view of a form for producing ice. The form includes a structural component110and a base component120. As depicted inFIG.4, the structural component110and the base component120are formed such that the structural component110may slide on to the base component120. The structural component110comprises three sides that may combine with the base and the side of the base component120to form a five-sided structure having a base. The base component120includes two lips wherein one lip is attached to the base of the base component and one lip is attached to the side of the base component120.

In an implementation, at least one of the three sides forming the structural component110is tapered such that a bottom area formed by the three sides of the structural component110is smaller than a top area formed by the three sides of the structural component110. In an implementation, the side of the base component120is angled to form an obtuse angle with respect to the base of the base component. In either of these implementations the form is configured to ensure that a liquid within the confines of the form freezes first on the bottom. Ensuring the liquid freezes first on the bottom can improve the structure of the frozen liquid such that it is less likely to break or crumble under stress.

In an implementation, the side of the base component120forms a right angle, or a near-right angle, with the base of the base. In an implementation, the sides are straight and a bottom area formed by the three sides is similar to a top area formed by the three sides.

FIG.5illustrates an aerial perspective view of a form for producing ice. As illustrated inFIG.5, the structural component110may slide into the base component120. The side124of the base component120may combine with the plurality of sides of the structural component110to form a five-sided structure having a base. The base component may include two lips, one lip attached to the base of the base component120and one lip attached to the side124of the base component120. The lip attached to the base may extend up an exterior of the structural component110and help secure the structural component110in place. The lip attached to the side of the base component120may extended outward from the form100. As depicted, two vertical expansion joints S1and S2are formed between the plurality of sides and the base component to allow for expansion of the ice during freezing.

FIG.6illustrates an aerial perspective view of a form for producing ice. As illustrated inFIG.6, a bag comprising a liquid may be placed within the five-sided form. The form100may hold the bag comprising the liquid for an extended period such that the liquid freezes in the same shape as the form.

FIG.7illustrates an aerial perspective view of a plurality of forms for producing ice located in a freezer. As illustrated inFIG.7, a bag comprising a liquid may be placed within the five-sided form for an extended period such that the liquid freezes in the same shape as the form. In an implementation, the side124of the base component120forms an obtuse angle with respect to the base122of the base component120. In an implementation, the three sides112,114of the structural component110form right angles or near-right angles with one another. In such an implementation, the obtuse angle formed in the base component120ensures that the area of the form located near the base122is smaller than an upper area of the form located near the open side. In such an implementation, the form promotes a liquid to freeze near the base122before the liquid freezes near the top at the open side. This procedure for freezing a liquid can be important for producing a structurally sound solid that can withstand stress without crumbling or breaking.

FIG.8illustrates an aerial perspective view of a plurality of forms for producing ice located in a freezer, including one fully formed ice block. As illustrated inFIG.8, a bag comprising a liquid may be placed within the five-sided structure formed by the form100. The liquid may be permitted to freeze within the confines of the five-sided structure and then a frozen solid may be removed from the form100. As illustrated inFIG.8, a bag comprising a frozen solid is being lifted from a five-sided form. The solid within the bag is frozen to the same shape formed by the five-sided form.

In an implementation, the form100is constructed of sheet metal. In such an implementation, the structural component110and the base component120are cut from sheet metal and bent to form the proper structure. The structural component110is bent to form three sides. The base component120is bent to form a lip, a base, a side, and an additional lip. In such an implementation, a number of forms100may be constructed of a single piece of sheet metal and shaped to the correct structure. Further in such an implementation, the form100may withstand fluctuations in temperature as the form is placed within a cold environment, such as a sub-zero environment, and placed in a warmer environment such as room temperature. It should be appreciated that the form100may be constructed of any suitable material, such as sheet metal, a ceramic, a concrete, a polycarbonate, and so forth.

Turning toFIGS.9-14, a second illustrative embodiment of an ice block form1000in accordance with the disclosure is depicted. Form100is generally formed as a box having floor defined by a bottom or base member1006, and an open top1100defined by sidewalls rising from the bottom1006. As depicted, form1000may be formed as a generally rectangular bock have two opposite sidewalls1002A and1002B that are relatively narrower to define first and second ends of the rectangular form and two opposite sidewalls1004A and1004B extending therebetween that are relatively wider to define the longer sides of the rectangular form. It will be appreciated that the number of sides and the relative widths thereof may vary based on the intended use of the resulting ice blocks. For example, the depicted embodiment may produce generally rectangular ice blocks having a certain size and shape for use in a block ice shaver for the production of confectionaries. For uses where different shaped blocks (such as tri-agonal, hexagonal, etc.) would be desired, differently shaped forms may be used.

Each sidewall1002A,1002B,1004A, or1004B is joined to the bottom1006and rises therefrom generally perpendicularly. In the depicted embodiment, each sidewall may be disposed at an angle of generally about 90 degrees to the adjacent sidewall. One or more vertical expansion joints S10, S12, S14and S16may be disposed at a corner of the form1000, formed as a slit extending between the respective sidewalls forming that corner and extending from the bottom1006to the top of the form1000. In the depicted embodiment there are four vertical expansion joints, but it will be appreciated that this number may be varied depending on the particular usage of a form1000.

The vertical expansion joints allow the sidewalls to move with respect to one another, providing flexibility for the expansion of a liquid held in a flexible plastic liner within the form1000during freezing. This movement also facilitates removal of an ice block for use. Additionally, the flexibility may allow for multiple forms1000to be stacked inside one another for storage when not in use.

Each sidewall1002A,1002B,1004A and1004B may have a lip or flange1012A,1012B,1014A, or1014B, respectively extending outwards at a generally perpendicular angle therefrom at the top end thereof. Each flange may extend for a portion or the entire width of its respective sidewall and may have rounded corners. The flanges1012A,1012B,1014A, and1014B are generally coplanar.

In an implementation, the form1000may be constructed of sheet metal.FIG.15depicts a “blank”1600cut from an appropriate gauge sheet metal that may be bent to a proper shape to form the proper structure. The location of required bends are indicated by dashed lines. The resulting structures are indicated by corresponding reference numerals. The blank1600is bent to form each sidewall and lip or flange. The use of a single piece of sheet metal shaped to the correct structure can ease manufacture and reduce costs. Further in such an implementation, the form1000may withstand fluctuations in temperature as the form is placed within a cold environment, such as a sub-zero environment, and placed in a warmer environment such as room temperature. It should be appreciated that in other embodiments, the form1000may be constructed of any suitable material, such as sheet metal, a ceramic, a concrete, a polycarbonate, and so forth.

While the dimensions of form1000can vary based on the size of the desired frozen block, in one embodiment the form1000may have a height and a width of between 3 and 12 inches and a length of between 10 and 25 inches. In one particular implementation, it may have a height and a width of about 6.5 inches and a length of about 19 inches to produce a block for use with an ice block shaver.

Turning toFIGS.16through18, a stacking member2000for use with form1000in a system for forming blocks. Stacking member2000may be formed as a generally planar body2001having a first surface2002, which is generally flat and may be referred to as an “upper surface” and an opposite second surface2003, which is generally flat and may be referred to as a “lower surface”. Body2001may be sized and configured to cover the open top1100of an ice block form when placed thereover, with the second surface2001placed on the flanges1012A,1012B,1014A and1014B.

A plurality of elevation structures2004may be disposed on the first surface2002. In the depicted embodiment, there are four elevation structures,2004A,2004B,2004C and2004D. It will be appreciated that the number of elevation structures may vary depending on the particular embodiment, but needs to be sufficient to support an ice form1000that is filled with a liquid above the first surface2002while maintaining a sufficient gap therebetween as discussed further herein. In the depicted embodiment, the elevation structures2004A,2004B,2004B, and2004C may be formed as four columnar bodies attached to the first surface2002. For example, columnar feet or stops that may be formed from resilient material such as a rubberized columnar bumper attached to the planar body2001using a bolt may be used. It will be appreciated that such structures are merely exemplary and any suitable structure may be used.

On the opposite second surface2003there may be disposed a plurality of alignment structures2005. In the depicted embodiment, there may be four alignment structures2005A,2005B,2005C and2005D. The alignment structures may be structures that extend out from the second surface and are positioned to correspond to the open top1100of an ice block form1000to be inserted therein and reside near the sidewalls thereof. in the depicted embodiment, there are four alignment structures that will reside near or may even abut, the four corners of an ice block form1000upon insertion therein to maintain the stacking plate2000in the desired position. In the depicted embodiment, the alignment structures may be formed as caps or acorn nuts placed on the threaded shaft of a bolt retaining the elevation structures. Accordingly, the placement of the alignment structures may correspond to the elevation structures.

Turning toFIGS.19,20A and20B, the use of a system including forms1000and stacker plates2000to form ice blocks is depicted. As shown inFIG.19, a plastic liner2300, such as a plastic bag, may be placed in the form1000through the open top1100and spread out to the corners along the bottom and sidewalls. The liner2300may be spread over the flanges. A liquid L to be frozen may then be placed in the form, contained in the liner and filling the form1000to an appropriate depth. The top of the liner may then be gathered, and where desired, closed to isolate the liquid L.

A stacker plate2000may be used to cover the open top1000of the ice block form2000. The stacker plate2000resides on the flanges and the alignment member2003extend into the open top and retain the stacker plate in position thereon.

As depicted best inFIG.20B, the stacker plate2000defines an insulative space2350above the liquid in the form1000between the upper surface of the liquid and the lower surface of the stacker plate due to the air in such space that is isolated from the surrounding freezer. This space results leads to the production of a desirable dense ice structure by encouraging the liquid L to freeze in a “bottom up” manner with the final stages of freezing more likely to occur near the upper surface to avoid trapping unfrozen liquid in the center of the block during freezing, leading to creaking and an unstable structure.

In embodiments sized as discussed above, the insulative space may have a depth of from about ½ to about 1 inch. It will be appreciated that this size may be adjusted as the size of the system varies in order to maintain an appropriate ratio.

A second ice form1000B may then be placed over the stacker plate residing on the elevation members2004to provide a flow space2352therebetween while also supporting the base1006of the second ice block form1000. The flow space2350is open to the environment around the forms1000and100A and allows the movement of air in the freezer where the forms are placed to underneath the upper form. This encourages the initiation of freezing the liquid L through the conductive bottom1006of the form1000A towards the top insulative space2350at the top of the form in a freezer in which they are placed to result in a dense ice block of relatively uniform structure.

It will be appreciated that the uppermost ice block form1000in a set of stacked forms may have a stacker plate2000placed thereover to provide the insulative space. Additionally, where desirable for a particular commercial or residential style freezer where the system is used, a stacker plate2000may be placed underneath the lowest form1000in the stack to provide a flow space2352underneath for uniform freezing in comparison to the forms stacked thereon. Additionally, it will be appreciated that the number of forms1000and stacker plates used in a particular stack may vary based on the size of the freezer where it is used. For example, where a commercial chest freezer would accommodate a stack of three or four ice block forms1000and associated stacker plates2000, that number of assemblies may be stacked. Parallel stacks of the systems next to one another in such a freezer may also be utilized to maximize space.

It will be appreciated that methods of making ice blocks using the systems and components discussed herein and including steps such as placing a liner in a form, filling the liner in the form with a desired liquid, pulling the filled liner taut to remove wrinkles therein to achieve a smoother sider block, placing stacker plates and form in a freezer to obtain proper insulative and flow spaces, freezing the liquid, and/or removing ice blocks from the forms using the expansion joints to flex the form sidewalls to facilitate removal are included within the teachings of this disclosure.

The foregoing description has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. Further, it should be noted that any or all of the aforementioned alternate implementations may be used in any combination desired to form additional hybrid implementations of the disclosure.

It should be noted that embodiments shown in the figures and described herein are intended to be exemplary and that any variations in the size and the relative proportions of the individual components fall within the scope of this disclosure.

Further, although specific implementations of the disclosure have been described and illustrated, the disclosure is not to be limited to the specific forms or arrangements of parts so described and illustrated. The scope of the disclosure is to be defined by the claims appended hereto, any future claims submitted here and in different applications, and their equivalents.