ICE MAKING ASSEMBLIES AND METHODS FOR MAKING CLEAR ICE

Abstract

Ice making assemblies and methods for making ice, and particularly clear ice, are provided herein. The methods of making ice may include providing a volume of water within a mold cavity defined by an ice mold. The volume of water may be demineralized. Additionally or alternatively, the mold cavity may be pre-chilled to a sub-freezing temperature. Also additionally or alternatively, a freezer chamber in which the ice mold is provided may be directed to one or more sub-freezing temperatures while the volume of water is within the mold cavity.

Description

FIELD OF THE INVENTION

The present subject matter relates generally to ice making appliances and methods, and more particularly to appliances and methods for making substantially clear ice.

BACKGROUND OF THE INVENTION

In domestic and commercial applications, ice is often formed as solid cubes, such as crescent cubes or generally rectangular blocks. The shape of such cubes is often dictated by the environment during a freezing process. For instance, an ice maker can receive liquid water, and such liquid water can freeze within the ice maker to form ice cubes. In particular, certain ice makers include a freezing mold that defines a plurality of cavities. The plurality of cavities can be filled with liquid water, and such liquid water can freeze within the plurality of cavities to form solid ice cubes.

In typical ice making appliances, water in the cavities begins to freeze and solidify first from its sides and outer surfaces (including a top water surface that may be directly exposed to freezing air), and then in and through the remaining volume of water occupying the cavity. In other words, the exterior surfaces of an ice cube freeze first. However, impurities and gases contained within the water to be frozen may be trapped in a solidified ice cube during the freezing process. For example, impurities and gases may be trapped near the center or the bottom surface of the ice cube, due to their inability to escape and as a result of the freezing liquid to solid phase change of the ice cube surfaces. Separate from or in addition to the trapped impurities and gases, a dull or cloudy finish may form on the exterior surfaces of an ice cube (e.g., during rapid freezing of the ice cube). Generally, a cloudy or opaque ice cube is the resulting product of typical ice making appliances.

Although typical ice cubes may be suitable for a number uses, such as temporary cold storage and rapid cooling of liquids in a wide range of sizes, they may present a number of disadvantages. As an example, impurities and gases trapped within an ice cube may impart undesirable flavors into a beverage being cooled (i.e., a beverage in which the ice cube is placed) as the ice cube melts. Such impurities and gases may also cause an ice cube to melt unevenly or faster (e.g., by increasing the exposed surface area of the ice cube). Evenly-distributed or slow melting of ice may be especially desirable in certain liquors or cocktails. Additionally or alternatively, it has been found that substantially clear ice cubes (e.g., free of any visible impurities or dull finish) may provide a unique or upscale impression for the user.

Accordingly, further improvements in the field of ice making would be desirable. In particular, it may be desirable to provide an appliance or methods for rapidly and reliably producing substantially clear ice.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In exemplary aspects of the present disclosure, a method of making ice is provided. The method of making ice may include providing a volume of water within a mold cavity defined within an insulated ice mold, the insulated ice mold being positioned within a freezer chamber, the insulated ice mold comprising an insulated sidewall defining a vertical opening in fluid communication between the freezer chamber and the mold cavity; maintaining the freezer chamber below a first sub-freezing temperature during an ice formation cycle as a portion of the volume of water freezes to a frozen volume; and directing the freezer chamber to a second sub-freezing temperature during an ice maintenance cycle while the frozen volume remains within the freezer chamber, the second sub-freezing temperature being above the first sub-freezing temperature, the ice maintenance cycle being subsequent to the ice formation cycle.

In exemplary aspects of the present disclosure, a method of making ice is provided. The method of making ice may include providing a demineralized volume of water; dissolving a nucleation additive within the demineralized volume of water to generate a treated volume of water; providing the treated volume of water within a mold cavity of an ice mold positioned within a freezer chamber; and freezing a portion of the treated volume of water within the mold cavity.

In still other exemplary aspects of the present disclosure, a method of making ice is provided. The method of making ice may include chilling an ice mold defining a mold cavity to a sub-freezing temperature within a freezer chamber; providing a volume of water within the mold cavity; and initiating seed crystal formation at a bottom portion of the mold cavity after providing the volume of water within the mold cavity.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

FIG. 1 provides a side plan view of an ice making appliance according to exemplary embodiments of the present disclosure.

FIG. 2 provides a schematic view of an ice making assembly according to exemplary embodiments of the present disclosure.

FIG. 3 provides a cross-sectional schematic view of a portion of an ice making assembly according to exemplary embodiments of the present disclosure.

FIG. 4 provides a schematic view of a water distribution assembly for an ice making assembly according to an example embodiment of the present disclosure.

FIG. 5 provides a cross-sectional view of an ice mold according to exemplary embodiments of the present disclosure.

FIG. 6 provides a magnified view of a portion of the exemplary ice mold of FIG. 5.

FIG. 7 provides a cross-sectional view of an ice mold according to exemplary embodiments of the present disclosure.

FIG. 8 provides a cross-sectional view of an ice mold according to exemplary embodiments of the present disclosure.

FIG. 9 provides a flow chart illustrating a method of operating an ice making appliance in accordance with an exemplary embodiment of the present disclosure.

FIG. 10 provides a flow chart illustrating a method of operating an ice making appliance in accordance with an exemplary embodiment of the present disclosure.

FIG. 11 provides a flow chart illustrating a method of operating an ice making appliance in accordance with an exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

Reference will now be made in detail to present embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the invention. As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “upstream” and “downstream” refer to the relative flow direction with respect to fluid flow in a fluid pathway. For example, “upstream” refers to the flow direction from which the fluid flows, and “downstream” refers to the flow direction to which the fluid flows. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”).

Turning now to the figures, FIG. 1 provides a side plan view of an ice making appliance 100, including an ice making assembly 102. FIG. 2 provides a schematic view of ice making assembly 102. FIG. 3 provides a cross-sectional schematic view of a portion of ice making assembly 102.

Generally, ice making appliance 100 includes a cabinet 102 (e.g., insulated housing) and defines a mutually orthogonal vertical direction V, lateral direction, and transverse direction. The lateral direction and transverse direction may be generally understood to be horizontal directions H. As shown, cabinet 102 defines one or more chilled chambers, such as a freezer chamber 106. In certain embodiments, such as those illustrated by FIG. 1, ice making appliance 100 is understood to be formed as, or as part of, a stand-alone freezer appliance. It is recognized, however, that additional or alternative embodiments may be provided within the context of other refrigeration appliances. For instance, the benefits of the present disclosure may apply to any type or style of a refrigerator appliance (e.g., a top mount refrigerator appliance, a bottom mount refrigerator appliance, a side-by-side style refrigerator appliance, etc.) that includes a freezer chamber. Consequently, the description set forth herein is for illustrative purposes only and is not intended to be limiting in any aspect to any particular chamber configuration.

Ice making appliance 100 generally includes an ice making assembly 102 on or within freezer chamber 106. In some embodiments, ice making appliance 100 includes a door 105 that is rotatably attached to cabinet 102 (e.g., at a top portion thereof). As would be understood, door 105 may selectively cover an opening defined by cabinet 102. For instance, door 105 may rotate on cabinet 102 between an open position (not pictured) permitting access to freezer chamber 106 and a closed position (FIG. 2) restricting access to freezer chamber 106.

A user interface panel 108 is provided for controlling the mode of operation. For example, user interface panel 108 may include a plurality of user inputs (not labeled), such as a touchscreen or button interface, for selecting a desired mode of operation. Operation of ice making appliance 100 can be regulated by a controller 110 that is operatively coupled to user interface panel 108 or various other components, as will be described below. User interface panel 108 provides selections for user manipulation of the operation of ice making appliance 100 such as (e.g., selections regarding chamber temperature, ice making speed, or other various options). In response to user manipulation of user interface panel 108 or one or more sensor signals, controller 110 may operate various components of the ice making appliance 100 or ice making assembly 102.

Controller 110 may include a memory and one or more microprocessors, CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of ice making appliance 100. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. Alternatively, controller 110 may be constructed without using a microprocessor (e.g., using a combination of discrete analog or digital logic circuitry; such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like; to perform control functionality instead of relying upon software).

Controller 110 may be positioned in a variety of locations throughout ice making appliance 100. In optional embodiments, controller 110 is located within the user interface panel 108. In other embodiments, the controller 110 may be positioned at any suitable location within ice making appliance 100, such as for example within cabinet 102. Input/output (“I/O”) signals may be routed between controller 110 and various operational components of ice making appliance 100. For example, user interface panel 108 may be in communication with controller 110 via one or more signal lines or shared communication busses.

As illustrated, controller 110 may be in communication with the various components of ice making assembly 102 and may control operation of the various components. For example, various valves, switches, etc. may be actuatable based on commands from the controller 110. As discussed, user interface panel 108 may additionally be in communication with the controller 110. Thus, the various operations may occur based on user input or automatically through controller 110 instruction.

As will be described in detail below, ice making appliance 100 includes a sealed cooling system 112 for executing a vapor compression cycle for cooling air within ice making appliance 100 (e.g., within freezer chamber 106). Sealed cooling system 112 includes a compressor 114, a condenser 116, an expansion device 118, and an evaporator 120 connected in fluid series and charged with a refrigerant. As will be understood by those skilled in the art, sealed cooling system 112 may include additional components (e.g., at least one additional evaporator, compressor, expansion device, or condenser). Moreover, at least one component (e.g., evaporator 120) is provided in thermal communication with freezer chamber 106 to cool the air or environment within freezer chamber 106. Optionally, evaporator 120 is mounted within freezer chamber 106, as generally illustrated in FIG. 1.

Within sealed cooling system 112, gaseous refrigerant flows into compressor 114, which operates to increase the pressure of the refrigerant. This compression of the refrigerant raises its temperature, which is lowered by passing the gaseous refrigerant through condenser 116. Within condenser 116, heat exchange with ambient air takes place so as to cool the refrigerant and cause the refrigerant to condense to a liquid state.

Expansion device (e.g., a mechanical valve, capillary tube, electronic expansion valve, or other restriction device) 118 receives liquid refrigerant from condenser 116. From expansion device 118, the liquid refrigerant enters evaporator 120. Upon exiting expansion device 118 and entering evaporator 120, the liquid refrigerant drops in pressure and vaporizes. Due to the pressure drop and phase change of the refrigerant, evaporator 120 is cool relative to freezer chamber 106. As such, cooled air is produced and refrigerates freezer chamber 106. Thus, evaporator 120 is a heat exchanger which transfers heat from air passing over evaporator 120 to refrigerant flowing through evaporator 120.

Optionally, ice making appliance 100 further includes a valve 122 for regulating a flow of liquid water to ice making assembly 102. Valve 122 is selectively adjustable between an open configuration and a closed configuration. In the open configuration, valve 122 permits a flow of liquid water to ice making assembly 102. Conversely, in the closed configuration, valve 122 hinders the flow of liquid water to an ice mold 130.

In certain embodiments, ice making appliance 100 also includes an air handler 124 mounted within (or otherwise in fluid communication with) freezer chamber 106. Air handler 124 may be operable to urge a flow of chilled air (i.e., active airflow—as indicated at arrows 126) within freezer chamber 106. Moreover, air handler 124 can be any suitable device for moving air. For example, air handler 124 can be an axial fan or a centrifugal fan.

As shown, an ice mold 130 may be provided within freezer chamber 106. In particular, ice mold 130 may be removably positioned within freezer chamber 106 such that a user may selectively place ice mold 130 within freezer chamber 106 (e.g., during ice making operations) and remove ice mold 130 from freezer chamber 106 (e.g., to remove ice billets from ice mold 130) as desired. As shown, ice mold 130 includes one or more sidewalls 132 that define one or more mold cavities 134 in which water may be received and ice cubes or billets (e.g., solid masses or blocks of ice that may be further melted to a final shape) may be formed. Optionally, the mold cavities 134 may be defined as open voids in fluid communication with freezer chamber 106. For instance, the sidewalls 132 may define a vertical opening 140 corresponding to each mold cavity 134 through which air or water may pass. The vertical opening 140 may, for example, have a horizontal diameter that is equal to or greater than the horizontal diameter of the mold cavity 134. A base wall 142 may extend below the sidewalls 132 to further define mold cavities 134 and, for example, ensure that water does not leak or pass from mold cavity 134 (e.g., during ice making operations).

Generally, it is understood that ice mold 130 may be formed from any suitable material. In some embodiments, one or more thermally insulating materials are utilized to form ice mold 130. The sidewalls 132 may be insulated sidewalls 132 and the ice mold 130 may be an insulated ice mold 130. As an example, one or more of the sidewalls 132 may define a sealed insulation volume. The sealed insulation volume may generally prevent the passage of air or oxygen to or from a volume within each sidewall 132 (e.g., as a substantially evacuated a vacuum or a volume filled with a set mass of gas, such as nitrogen, oxygen, argon, or a suitable inert gas). As another example, one or more of the sidewalls 132 may be formed or filled with a solid insulating material (e.g., a rigid polyurethane insulating foam) to hinder to heat transfer between each mold cavity 134 and its surrounding environment (e.g., freezer chamber 106).

When assembled, air handler 124 may be positioned above (or otherwise located at a position to) direct an active airflow 126 across a top portion of ice mold 130 (e.g., perpendicular to vertical opening 140). Thus, an active airflow 126 may be selectively motivated across ice mold 130, thereby accelerating heat transfer from ice mold 130 at the top portion thereof. For instance, air handler 124 may be configured to motivate the active airflow 126 at one or more predetermined flow rates (e.g., volumetric flow rates) within freezer chamber 106.

In some embodiments, one or more sensors are mounted on or within ice mold 130. As an example, a temperature sensor 144 may be mounted to ice mold 130. Temperature sensor 144 may be electrically coupled to controller 110 and configured to detect the temperature within ice mold 130. Temperature sensor 144 may be formed as any suitable temperature detecting device, such as a thermocouple, thermistor, etc. Optionally, temperature sensor 144 may be mounted at a predetermined height along one of the sidewalls 132. In some such embodiments, the predetermined height is a ballast height 148 positioned below the top portion of ice mold 130.

During use (e.g., during ice making operations), a liquid ballast 150 may form on top of a frozen volume (e.g., ice cube or billet) within mold cavity 134. Advantageously, impurities within the volume of water from which the frozen volume is formed may accumulate within the liquid ballast 150 as the volume of water freezes. Detection of a predetermined temperature at the temperature sensor 144 (e.g., at the ballast height 148) may indicate the frozen volume has reached the ballast height 148. Optionally, controller 110 may be configured to adjust one or more operations of the ice making assembly 102 in response to determining that the ice mold 130 has frozen to the ballast height 148.

In additional or alternative embodiments, a pressure sensor 146 is mounted to ice mold 130. Pressure sensor 146 may be formed as any suitable pressure detecting device, such as a piezoresistive, capacitive, electromagnetic, piezoelectric, or optical pressure detecting device. During use, detection of a predetermined pressure increase at the pressure sensor 146 (i.e., at the ballast height 148) may indicate that a desired portion of the volume of water within mold cavity 134 has frozen (i.e., become a frozen volume). Optionally, controller 110 may be configured to adjust one or more operations of the ice making assembly 102 in response to determining the predetermined pressure increase has been reached.

In optional embodiments, a removable sleeve 152 is provided for selective insertion/removal within mold cavity 134. As shown, removable sleeve 152 may shaped to generally complement the surfaces of sidewalls 132 and base wall 142 that define mold cavity 134. Removable sleeve 152 may thus form a complementary opening to vertical opening 140. During use, a volume of water may be provided to removable sleeve 152 and ice may be formed therein (i.e., as the volume of water transitions to a frozen volume). Once a volume of water is frozen (e.g., as an ice cube or billet), removable sleeve 152 and the frozen volume may be removed together from ice mold 130.

Turning now to FIG. 4, a schematic view of an example water distribution assembly 154 is provided. Water distribution assembly 154 may be included with or as part of ice making assembly 102 (FIG. 3), as described above. In some such embodiments, ice making operations include providing or flowing water from a water distribution assembly 154 and to ice mold 130 (e.g., within mold cavity 134—FIG. 3).

In certain embodiments, a prefilter cartridge 160 or divider valve 162 are positioned upstream of ice mold 130. Prefilter cartridge 160 may be an activated carbon filter configured to remove sediment or organic material from water supplied thereto. Water received from a water source 164 (e.g., domestic water grid or well) may thus be forced through prefilter cartridge 160 before being directed to ice making assembly 102.

In optional embodiments, water may be introduced to water reservoir 166 (e.g., mounted on cabinet 102, within cabinet 102, or at another location spaced apart from cabinet 102—FIG. 1). A water recirculation line 168 may generally extend between water reservoir 166 or water source 164 and ice mold 130. Optionally, water recirculation line 168 may extend into the volume defined by water reservoir 166. Water recirculation line 168 may further extend in fluid communication between water reservoir 166 and water distribution outlet or manifold 170. In some such embodiments, a pump 172 is positioned along water recirculation line 168 to motivate water from within reservoir 166 to water distribution manifold 170 through water recirculation line 168. Additionally or alternatively, valve 122 (FIG. 2) may be provided in fluid communication between water source 164 and manifold 170 (e.g., with or without reservoir 166, pump 172, or any other portion of water distribution assembly 154) to control the flow of water to ice mold 130.

In some embodiments, a deionization filter 174 is positioned along water recirculation line 168. For instance, deionization filter 174 may be positioned upstream from the water distribution manifold 170 (e.g., in fluid communication therewith). Deionization filter 174 is generally configured to demineralize water or otherwise remove dissolved solids, such as inorganic salts of sodium and chlorine ions. Moreover, deionization filter 174 may include an anion resin and a cation resin. Optionally, deionization filter 174 may be a mixed-bed filter wherein the anion and cation resins are commingled.

In some embodiments, an organic compound filter 176 is positioned in fluid communication with ice mold 130 (e.g., as an activated carbon filter). Organic compound filter 176 may be in fluid communication between the deionization filter 174 and the water distribution manifold 170. In other words, organic compound filter 176 may be downstream from deionization filter 176. Optionally, organic compound filter 176 may be contained within the same filtration cartridge as deionization filter 174. Alternatively, organic compound filter 176 may include a discrete cartridge body spaced apart from deionization filter 174 along water recirculation line 168.

As illustrated, one or more conductivity sensors 180 may be provided in fluid communication with the water source 164. For instance, a conductivity sensor 180 may be positioned along water recirculation line 168 (e.g., downstream of deionization filter 174 or organic compound filter 176). Conductivity sensor 180 may be operably connected (e.g., electrically coupled) to controller 110. Moreover, conductivity sensor 180 may be configured to detect a value of fluid conductivity of water within assembly. Based on conductivity values detected at conductivity sensor 180, controller 110 may determine that deionization filter 174 has reached the end of a filter lifecycle (e.g., and should be replaced). Optionally, controller 110 may be configured to automatically halt ice making assembly 102 or ice making operations according to one or more conductivity values detected at conductivity sensor 180. For instance, if controller 110 determines that a detected conductivity value exceeds a threshold conductivity value, controller 110 may halt or cease operation of ice making assembly 102 (FIG. 3)—e.g., at water distribution assembly 154.

In some embodiments, an additive dispenser 178 is provided in fluid communication with the water source 164. For instance, additive dispenser 178 may be positioned along water recirculation line 168, downstream from the filters 174, 176 and upstream from ice mold 130 (e.g., and manifold 170). Additive dispenser 178 may be configured to selectively add or incorporate nucleation additive within the water flowed to ice mold 130. For instance, additive dispenser 178 may be electrically coupled to controller 110. Controller 110 may be configured to direct additive dispenser 178 to release nucleation additive to the flow of water (e.g., such that a predetermined concentration of nucleation additive is reached within a volume of water (e.g., before it enters ice mold 130). In some embodiments, the nucleation additive is provided as a salt (e.g., sodium chloride) in, for instance, a suitable granular or liquid solution form.

Turning now to FIGS. 5 and 6, various views are provided of an ice mold 130 according to exemplary embodiments. As shown, mold cavity 134 generally extends from an upper portion 136 to a bottom portion 138. In some such embodiments, ice mold 130 includes multiple discrete mold bodies. For instance, a first mold body 182 and a second mold body 184 may be provided. Generally, first mold body 182 defines a first cavity portion 186 and second mold body 184 defines a second cavity portion 188. Although first and second mold bodies 182, 184 may be selectively separated (e.g., to remove an ice cube or billet from ice mold 130), when assembled, second cavity portion 188 is axially aligned (e.g., along the vertical direction V) with the first cavity portion 186. Thus, first and second cavity portions 186, 188 together define mold cavity 134. The vertical opening 140 may be defined above first and second cavity portions 186, 188 (e.g., in axial alignment therewith). When ice mold 130 is positioned within freezer chamber 106 (FIG. 1), vertical opening 140 or mold cavity 134 may be in fluid communication between mold cavity 134 and the freezer chamber 106.

In optional embodiments, first and second mold bodies 182, 184 are formed from a conductive material (e.g., stainless steel, aluminum, etc., including alloys thereof). In additional or alternative embodiments, one or more portions of the sealed cooling system 112 are in thermal communication with one or both of the mold bodies 182, 184 to selectively draw heat therefrom. In particular, the evaporator 120 may be in thermal communication (e.g., direct conductive contact, spaced apart direct engagement, etc.) with first mold body 182. For instance, first mold body 182 may be positioned on or above evaporator 120 such that heat is conducted from mold cavity 134 through first mold body 182 and to evaporator 120.

In certain embodiments, a seed column 190 is defined within ice mold 130. For instance, seed column 190 may be defined in fluid communication with mold cavity 134, such that a portion of the volume of water provided to mold cavity 134 may pass into the seed column 190. As shown, seed column 190 generally defines a fluid channel extending from (e.g., below) mold cavity 134. As an example, seed column 190 may extend downward (e.g., in the vertical direction V) from the bottom portion 138 of mold cavity 134. Seed column 190 may define a cross-sectional or horizontal width W (e.g., diameter perpendicular to the vertical direction V). A length E of the seed column 190 may be defined perpendicular to the horizontal width W (e.g., parallel to the vertical direction V). In some such embodiments, the length E is greater than horizontal width W. For instance, the length E may be at least twice as long as the horizontal width W. Optionally, the horizontal width W may be less than 0.125 inch (e.g., while still being large enough to permit liquid water therethrough under the force of gravity).

Turning now to FIGS. 7 and 8, various views are provided of an ice mold 130 according to other exemplary embodiments. As shown, mold cavity 134 generally extends from an upper portion 136 to a bottom portion 138. In some such embodiments, ice mold 130 includes multiple discrete mold bodies. For instance, a first mold body 182, a second mold body 184, and a third mold body 192 may be provided. Generally, first mold body 182 defines a first cavity portion 186 and second mold body 184 defines a second cavity portion 188. Although first and second mold bodies 182, 184 may be selectively separated (e.g., to remove an ice cube or billet from ice mold 130), when assembled, second cavity portion 188 is axially aligned (e.g., along the vertical direction V) with the first cavity portion 186. Thus, first and second cavity portions 186, 188 together define mold cavity 134. The vertical opening 140 may be defined above first and second cavity portions 186, 188 (e.g., in axial alignment therewith). When ice mold 130 is positioned within freezer chamber 106 (FIG. 1), vertical opening 140 or mold cavity 134 may be in fluid communication between mold cavity 134 and the freezer chamber 106.

As shown, third mold body 192 may be selectively inserted or positioned within mold cavity 134 (e.g., through vertical opening 140). Third mold body 192 generally extends (e.g., along the vertical direction V) between an upper surface 194 and a lower surface 196. When positioned within mold cavity 134, the lower surface 196 of third mold body 192 may form a complementary recess 198 (e.g., axially aligned with first cavity portion 186 along the vertical direction V). Optionally, the portion of the lower surface 196, such as a radial edge, may rest on or above the first mold body 182. In turn, complementary recess 198 and first cavity portion 186 may generally define a volume or negative of the shape that an ice cube or billet frozen within mold cavity 134 may assume.

In optional embodiments, first, second, and third mold bodies 182, 184, 186 are formed from a conductive material (e.g., stainless steel, aluminum, etc., including alloys thereof). In additional or alternative embodiments, one or more portions of the sealed cooling system 112 are in thermal communication with one or both of the mold bodies 182, 184 to selectively draw heat therefrom. In particular, the evaporator 120 may be in thermal communication (e.g., direct conductive contact, spaced apart direct engagement, etc.) with first mold body 182. For instance, first mold body 182 may be positioned on or above evaporator 120 such that heat is conducted from mold cavity 134 through first mold body 182 and to evaporator 120.

In some embodiments, a striker 210 is selectively engaged with one or more of the mold bodies 182, 184, 186 (e.g., when assembled). In particular, striker 210 may be configured to selectively impact (e.g., collide with) the ice mold 130 to agitate the mold cavity 134 below the upper portion 136 thereof. Striker 210 may be provided as a rigid element formed from any suitable material. Thus, the impact of striker 210 on ice mold 130 transfer a collision or impact force to mold cavity 134.

As illustrated in FIG. 7, in certain embodiments, striker 210 is positioned outside of mold cavity 134. For instance, striker 210 may be directed towards first mold body 182. Optionally, a motor or actuator 212 may be mechanically coupled to striker 210 and configured to selectively move striker 210 (e.g., in a linear direction or horizontal direction H) against an outer surface 216 of first mold body 182. As shown, the outer surface 216 is formed opposite from the inner surface 214 of the mold cavity 134 and is directed outward away from the mold cavity 134 (e.g., toward the surrounding environment). In some such embodiments, actuator 212 is operably coupled to the controller 110 (FIG. 1) and is configured to motivate or move striker 210 in response to one or more signals received from the controller 110. Moving striker 210 against first mold body 182 may generate a collision or impact force that is thus transferred through first mold body 182 and, for instance, to the volume of liquid water within mold cavity 134.

As illustrated in FIG. 8, in additional or alternative embodiments, striker 210 is positioned within mold cavity 134. For instance, striker 210 may be directed through second mold body 184 and third mold body 192 towards an inner surface 214 of first mold body 182. Optionally, a motor or actuator 212 may be mechanically coupled to striker 210 and configured to selectively move striker 210 (e.g., in a linear direction or vertical direction V) against first mold body 182. As an example striker 210 may be selectively moved against (e.g., impact or collide with) the bottom portion 138 of mold cavity 134. In some such embodiments, actuator 212 is operably coupled to the controller 110 (FIG. 1) and is configured to motivate or move striker 210 in response to one or more signals received from the controller 110. Moving striker 210 against first mold body 182 may generate a collision or impact force that is thus transferred, for instance, to the volume of liquid water within mold cavity 134.

Referring now to FIGS. 9 through 11, various methods (e.g., method 300, method 400, and method 500) may be provided for use with the ice making appliance 100 or ice making assembly 102 (FIG. 1) in accordance with the present disclosure. In some embodiments, such as the exemplary embodiments illustrated by methods 300, 400, and 500 all or some of the various steps of the method may be performed by controller 110 (FIG. 1). For example, controller 110 may, as discussed, be operably coupled to one or more of sealed cooling system 112, valve 122, control panel, air handler 124, pressure sensor 146, temperature sensor 144, additive dispenser 178, or actuator 212. During use, controller 110 may send signals to or receive signals from some or all of these components. Controller 110 may further be operably coupled to other suitable components of the appliance 100 to facilitate operation of the appliance 100 generally. The present methods may advantageously facilitate the formation or creation of substantially clear ice cubes or billets. Moreover, such methods may advantageously permit substantially clear ice to be produced in less than 14 hours (e.g., following initiation thereof).

FIGS. 9 through 11 depict steps performed in a particular order for purpose of illustration and discussion. Those of ordinary skill in the art, using the disclosures provided herein, will understand that (except as otherwise indicated) the steps of any of the methods disclosed herein can be modified, adapted, rearranged, omitted, or expanded in various ways without deviating from the scope of the present disclosure.

Turning now to FIG. 9, at 310, the method 300 may include providing a volume of water within the mold cavity defined within the ice mold. In some embodiments, the ice mold is an insulated ice mold. Thus, national may include one or more insulated sidewalls, as described above. Moreover, the insulated sidewalls may define vertical opening. The vertical opening may generally be exposed or uncovered (e.g., relative to surrounding environment). When positioned within the freezer chamber, the vertical opening may thus be in fluid communication between freezer chamber and the mold cavity.

It is understood that the volume of water provided to the mold cavity may be provided manually or, alternatively, automatically. For instance, when provided manually, the volume of water in mold cavity may be poured directly by a user supplying the water to mold cavity. By contrast, when provided automatically, the controller may control or actuate the valve of the ice making assembly to open, thereby permitting volume of water to flow to the mold cavity. Additionally or alternatively, the pump of the water distribution assembly may be activated, as described above. Although described as automatic, is understood that controller may operate (e.g., transmit one or more signals to the valve) in response to one or more user input signals received from the user interface. Moreover, it is understood that the volume of water may be provided to the mold cavity while the ice mold is positioned within or, alternatively, outside of freezer chamber. However, the purposes of the method 300, once the volume of water is provided within the mold cavity, the ice mold is understood to be positioned within the freezer chamber (e.g., for the duration of steps 320 and 330).

At 320, the method 300 may include maintaining the freezer chamber below a first sub-freezing temperature during an ice formation cycle. The ice formation cycle may be performed while the ice mold (and thereby the volume of water within the mold cavity) is positioned within the freezer chamber. Thus, the ice mold is maintained or held below the first sub-freezing temperature for the duration of the ice formation cycle as a portion of the volume of water freezes to a frozen volume (e.g., ice cube or billet). During the ice formation cycle, the freezer chamber may be maintained at a relatively stable temperature (e.g., between −10° Fahrenheit and 10° Fahrenheit). In some embodiments, the first sub-freezing temperature may be 10° Fahrenheit. In other embodiments, the first sub-freezing temperature may be 5° Fahrenheit. In further embodiments, the first sub-freezing temperature may be 0° Fahrenheit.

As described above, the sealed cooling system may be activated or otherwise directed to cool the freezer chamber. For instance, during the ice formation cycle, heat may be drawn from the freezer chamber or ice mold at the evaporator. As would be understood, the sealed cooling system may be selectively activated by the controller (e.g., based on one or more temperature signals received from a temperature sensor mounted to the ice making appliance or within the freezer chamber).

At 330, the method 300 may include directing the freezer chamber to a second sub-freezing temperature during an ice maintenance cycle. Generally, 330 is performed subsequent to 320 (e.g., immediately following completion of the ice formation cycle). Moreover, during 330, the frozen volume is understood to remain within the freezer chamber (e.g., within the mold cavity or separate therefrom in a discrete ice container). Thus, the present volume is maintained or held at the second sub-freezing temperature for the duration of the maintenance cycle.

The second sub-freezing temperature may be greater than the first sub-freezing temperature. In turn, transitioning from the ice formation cycle to the maintenance cycle may require releasing the temperature within the freezer chamber. Such an increase may occur gradually and as a result of natural heat absorption by the ice making appliance. Optionally, 330 may include deactivating limiting operation of the sealed cooling system. The sealed cooling system may continue to draw heat from the freezer chamber (e.g., through the evaporator), but at a rate less than would be provided during the ice formation cycle. The second sub-freezing temperature may be a relatively stable temperature (e.g., between 20° Fahrenheit and 32° Fahrenheit). In some embodiments, the first sub-freezing temperature may be 20° Fahrenheit. In other embodiments, the first sub-freezing temperature may be 25° Fahrenheit. In further embodiments, the first sub-freezing temperature may be 30° Fahrenheit.

In some embodiments, 330 is contingent upon completion of the ice formation cycle. In other words, the method 300 may include ensuring that the ice formation cycle is complete before initiating 330 and the ice maintenance cycle. Completion of the ice formation cycle may include determination of one or more predetermined conditions. As an example, the ice formation cycle may have predetermined time (e.g., span of time) after which the ice formation cycle expires. Thus the ice formation cycle may end upon the predetermined time elapsing. Optionally, the predetermined time may begin when the volume of water is provided within the freezer chamber (e.g., at 310). As another example, the ice formation cycle may end upon a predetermined condition being detected at the ice mold. Optionally, the predetermined condition may include detecting a set temperature been reached at the temperature sensor (e.g., at the ballast height). Detection of the set temperature may indicate that the frozen volume has reached (i.e., frozen to) the ballast height and is therefore at a desired size. Additionally or alternatively, the predetermined condition may include detecting a set pressure has been reached at the pressure sensor within the ice mold. Furthermore, it is understood that any other suitable predetermined condition for ascertaining the size of the frozen volume or extent to which the provided volume of water has frozen may be utilized.

In optional embodiments, method 300 includes directing an active airflow across the ice mold. For instance, as described above the air handler within the freezer chamber may be activated or rotated to motivate air within the freezer chamber to flow (i.e., as an active airflow) over or across the ice mold. The active airflow may be provided at one or more periods of the method 300. In particular, the active airflow may be provided at 320 or for the duration of the ice formation cycle. In some such embodiments, the active airflow is motivated a predetermined flow rate (e.g., volumetric flow rate). In other words, the flow rate of the active airflow may remain constant during the ice formation cycle. In other embodiments, active airflow is motivated at a variable flow rate. The flow rate may increase or decrease based one or more received signals or user inputs. For instance, the variable flow rate may be set according to a specific user input. Additionally or alternatively, the variable flow rate may be set automatically according to a sensed condition (e.g., one or more signals received from, for example, the temperature sensor or the pressure sensor mounted to the ice mold).

Optionally, the active airflow may further be provided at 330 or for the duration of the maintenance cycle (e.g., at a flow rate that is less than a flow rate during the ice formation cycle). Alternatively, the active airflow may be halted during 330 or for the duration of the maintenance cycle.

Turning now to FIG. 10, at 410, the method 400 may include providing a demineralized volume of water. For instance, the volume of water provided at 410 may be distilled water. Additionally or alternatively, the volume of water provided at 410 may be deionized water. In some such embodiments, 410 includes directing an initial volume of water through a deionization filter upstream from the ice mold, as described above.

At 420, the method 400 may include dissolving a nucleation additive within the demineralized volume of water. By dissolving the nucleation additive within the demineralized volume of water, a treated volume of water may be generated. The nucleation additive generally includes sediment or material for promoting ice nucleation during freezing. As an example, the nucleation additive may include or be provided as sodium chloride (e.g., in a granular form or as part of a concentrated solution). In certain embodiments, 420 includes setting a concentration of the nucleation additive within the treated volume of water to a predetermined level. Thus, the amount of nucleation additive dissolved within the treated volume of water may only be the amount necessary to achieve the predetermined level (e.g., ratio of nucleation additive to water). Optionally, the predetermined level may be between 50 parts per million (ppm) of Total Dissolved Solids (TDS) and 100 ppm of TDS. Advantageously, the level or amount of nucleation additive within the water may thus be controlled, regardless of the level or amount that would otherwise be available in a given geographic region.

In some embodiments, 420 includes manually mixing our adding the nucleation additive to the volume of demineralized water. In other embodiments, 420 includes automatically adding the nucleation additive to the volume of demineralized water (e.g., as directed by the controller). For instance, as described above, the additive dispenser may selectively direct or supply nucleation additive to the demineralized water as it is flowed to the ice mold.

At 430, the method 400 may include providing the treated volume of water within a mold cavity positioned within a freezer chamber. Thus, the treated volume of water generated at 420 may be flowed into the mold cavity and within the freezer chamber.

At 440, the method 400 may include freezing at least a portion of the treated volume of water within the mold cavity. In some such embodiments, freezing at 440 may include directing an ice formation cycle, as described above (e.g., with respect to the method 300). Optionally, an ice maintenance cycle may follow the ice formation cycle, as further described above. Advantageously, impurities or sediment within the treated volume of water may settle together at a nucleation site for the ice as it freezes into a substantially clear ice cube or billet. Moreover, a liquid ballast may form above a frozen volume within the mold cavity (e.g., without flash freezing at the subfreezing temperature of the ice mold). Sediment or impurities provided with the volume of water may thus accumulate within the liquid ballast (e.g., instead of within the frozen volume).

In optional embodiments, the method 400 includes agitating the ice mold. In particular, the ice mold may be agitated below the upper portion of the ice mold. The agitation may generally follow 430. Moreover, agitation may initiate nucleation or freezing of the treated volume of water. In some such embodiments, agitating the ice mold includes moving or actuating the striker to impact or collide with a portion of the ice mold (e.g., the first mold body), as described above.

Turning now to FIG. 11, at 510, the method 500 may include chilling the ice mold defining the mold cavity to a sub-freezing temperature within the freezer chamber. For instance, the sealed cooling system may be activated to draw heat from the ice mold within the freezer chamber. In some such embodiments, the sealed cooling system remains active until after a predetermined sub-freezing temperature is detected at the ice mold (e.g., by a temperature sensor mounted therein). In certain embodiments, the evaporator of the sealed cooling system is mounted in thermal communication (e.g., conductive contact) with, for example, the first mold body of the ice mold, as described above. During 510 (e.g., throughout the time period during which the ice mold is chilling towards a sub-freezing temperature), the mold cavity may remain substantially empty and free of a volume of water.

At 520, the method 500 may include providing a volume of water within the mold cavity. In particular, the volume of water is not provided until after the sub-freezing temperature is reached at the ice mold. In other words, the ice mold may be pre-chilled to the sub-freezing temperature. The volume of water may be poured, for example, manually or automatically dispensed to the mold cavity, as described above. The volume of water may be demineralized or distilled prior to being provided to the mold cavity. Optionally, the volume of water may be a demineralized or distilled volume of water when provided to the mold cavity. In certain embodiments, the volume of water will be prevented from freezing or nucleating instantly upon entering the mold cavity. Thus, 520 may include super cooling the volume of water within the mold cavity.

At 530, the method 500 may include initiating seed crystal formation at a bottom portion of the mold cavity after providing the volume of water within the mold cavity. In other words, 530 may occur subsequent to 520 or the super cooling of the volume of water.

In some embodiments, 530 includes providing a portion (e.g., less than all) of the volume of water within a seed column. As described above, the seed column may be in fluid communication with the mold cavity and, for example, extend therebelow. Advantageously, the portion of water within the seed column may freeze before the remaining volume of water within the mold cavity, thereby creating a nucleation site from which water within the mold cavity may freeze. Moreover, a liquid ballast may form above a frozen volume within the mold cavity (e.g., without flash freezing at the subfreezing temperature of the ice mold). Sediment or impurities provided with the volume of water may thus accumulate within the liquid ballast (e.g., instead of within the frozen volume).

In additional or alternative embodiments, 530 includes striking the inner surface of the ice mold. As described above, the inner surface forms a portion of the mold cavity. As also described above, the striker may extend through the mold cavity to selectively contact (e.g., impact or collide with) the inner surface to generate an impact force thereon. In particular, the striker may strike the inner surface of the first mold body and a bottom portion of the mold cavity (e.g., as motivated by the actuator). Striking the inner surface may cause the super cooled volume of water within the mold cavity to begin freezing (e.g., at the site at which the inner surface is struck), thereby creating a nucleation site from which water within the mold cavity may freeze.

In further additional or alternative embodiments, 530 includes striking the outer surface of the ice mold. As described above, the outer surface may be directed outward away from the mold cavity. As also described above, the striker may extend towards and selectively contact (e.g., impact or collide with) the outer surface to generate an impact force thereon. In particular, the striker may strike the outer surface of the first mold body (e.g., as motivated by the actuator). Striking the outer surface may cause the super cooled volume of water within the mold cavity to begin freezing, thereby creating a nucleation site from which water within the mold cavity may freeze.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A method of making ice comprising:

providing a volume of water within a mold cavity defined within an insulated ice mold, the insulated ice mold being positioned within a freezer chamber, the insulated ice mold comprising an insulated sidewall defining a vertical opening in fluid communication between the freezer chamber and the mold cavity;

maintaining the freezer chamber below a first sub-freezing temperature during an ice formation cycle as a portion of the volume of water freezes to a frozen volume; and

directing the freezer chamber to a second sub-freezing temperature during an ice maintenance cycle while the frozen volume remains within the freezer chamber, the second sub-freezing temperature being above the first sub-freezing temperature, the ice maintenance cycle being subsequent to the ice formation cycle.

2. The method of claim 1, further comprising directing an active airflow across the insulated ice mold.

3. The method of claim 2, wherein the active airflow is motivated at a predetermined flow rate during the ice formation cycle.

4. The method of claim 2, wherein the active airflow is motivated at a variable flow rate during the ice formation cycle.

5. The method of claim 4, wherein the variable flow rate is set according to a user input.

6. The method of claim 4, wherein the variable flow rate is set automatically according to a sensed condition at the insulated ice mold.

7. The method of claim 2, wherein the active airflow is halted during the ice maintenance cycle.

8. The method of claim 1, wherein the ice formation cycle ends upon a predetermined time elapsing.

9. The method of claim 1, wherein the ice formation cycle ends upon a predetermined condition being detected at the insulated ice mold.

10. A method of making ice comprising:

providing a demineralized volume of water;

dissolving a nucleation additive within the demineralized volume of water to generate a treated volume of water;

providing the treated volume of water within a mold cavity of an ice mold positioned within a freezer chamber; and

freezing a portion of the treated volume of water within the mold cavity.

11. The method of claim 10, wherein dissolving the nucleation additive comprises setting a concentration of the nucleation additive within the treated volume of water to a predetermined level.

12. The method of claim 10, wherein the nucleation additive comprises sodium chloride.

13. The method of claim 12, wherein dissolving the nucleation additive comprises setting a concentration of sodium chloride within the treated volume of water to a predetermined level, wherein the predetermined level is between fifty parts per million of total dissolved solids and one hundred parts per million of total dissolved solids.

14. The method of claim 10, wherein the mold cavity is defined within the ice mold to extend from an upper portion to a bottom portion, and wherein an active cooling system is positioned in thermal communication with the ice mold to selectively draw heat therefrom.

15. The method of claim 14, wherein the ice mold further defines a seed column extending below the mold cavity in fluid communication therewith, and wherein the seed column has a horizontal width and a vertical length at least twice as long as the horizontal diameter.

16. The method of claim 14, further comprising agitating the ice mold below the upper portion of the mold cavity following providing the treated volume of water.

17. A method of making ice comprising:

chilling an ice mold defining a mold cavity to a sub-freezing temperature within a freezer chamber;

providing a volume of water within the mold cavity; and

initiating seed crystal formation at a bottom portion of the mold cavity after providing the volume of water within the mold cavity.

18. The method of claim 17, wherein initiating seed crystal formation comprises providing a portion of the volume of water within a seed column extending below the mold cavity in fluid communication therewith.

19. The method of claim 17, wherein the ice mold comprises an inner surface defining the mold cavity and an outer surface facing away from the mold cavity, and wherein initiating seed crystal formation comprises striking the inner surface.

20. The method of claim 17, wherein the ice mold comprises an inner surface defining the mold cavity and an outer surface facing away from the mold cavity, and wherein initiating seed crystal formation comprises striking the outer surface.