ICE MOLD FOR A CLEAR ICE MAKING ASSEMBLY

Abstract

An ice making assembly includes an ice mold including two or more separable portions that collectively define one or more mold cavities. Each of the mold portions define a plurality of recessed passages that at least partially surround the mold cavity and are configured to receive evaporator conduit of a sealed refrigeration to cool the ice mold and facilitate formation of an ice billet.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is the National Stage Entry of and claims the benefit of priority under 35 U.S.C. § 371 to PCT Application Serial No. PCT/CN2020/128636 filed Nov. 13, 2020 and entitled ICE MOLD FOR A CLEAR ICE MAKING ASSEMBLY, which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present subject matter relates generally to ice making appliances, and more particularly to ice molds for an ice making appliance that produces large, clear pieces of 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. Specifically, certain ice makers include a freezing mold that defines a plurality of cavities that can be filled with liquid water that freezes within the plurality of cavities to form solid ice cubes. Typical solid cubes or blocks may be relatively small in order to accommodate a large number of uses, such as temporary cold storage and rapid cooling of liquids in a wide range of sizes.

Notably, ice formed using conventional ice making appliances often suffers from impurities and gases that are trapped within ice cubes during formation. These impurities and gases 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. In addition, these impurities and gases may cause an ice cube to melt unevenly or faster (e.g., by increasing the exposed surface area of the ice cube). In recent years, ice making appliances have been developed for forming relatively large ice billets in a manner that avoids trapping impurities and gases within the billet. In addition to forming ice that is more evenly-distributed or slower melting, these clear ice cubes (e.g., free of any visible impurities or dull finish) may provide a unique or upscale impression for the user.

Certain ice making appliances for forming large, clear ice billets utilize an inverted or upside-down mold and a spray nozzle that sprays water upwards into the mold cavity. In this manner, impurities fall back into a water basin while pure water slowly forms ice within the mold. In this regard, water in the cavities begins to freeze and solidify first from the sides and top surfaces, and slowly fills the remaining volume of the mold cavity. Notably, however, conventional ice molds used in such a system have limited cooling capacity, resulting in long ice formation times to achieve a clear ice billet. In addition, temperature distribution within such molds is very non-uniform, resulting in temperature gradients within the ice billet that cause cracking during formation or release.

Accordingly, further improvements in the field of ice making would be desirable. More specifically, a clear ice making mold assembly that can reduce ice formation times while reducing the likelihood of cracking would be particularly beneficial.

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 one exemplary embodiment, an ice making assembly is provided including an ice mold defining a mold cavity, wherein the ice mold defines a plurality of recessed passages that at least partially surround the mold cavity, a sealed refrigeration system including a condenser and an evaporator in serial flow communication with each other, the evaporator being positioned within the plurality of recessed passages to cool the ice mold, and a pump assembly for urging an ice-building spray into the ice mold to form an ice billet.

In another exemplary embodiment, a mold assembly for an ice making assembly is provided. The mold assembly includes an ice mold including a first portion and a second portion that are separable and define a mold cavity, wherein the ice mold defines a plurality of recessed passages that at least partially surround the mold cavity and are configured for receiving evaporator conduit.

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 simplified perspective view of an ice making assembly according to exemplary embodiments of the present disclosure.

FIG. 4 provides a cross-sectional, schematic view of the exemplary ice making assembly of FIG. 3.

FIG. 5 provides a cross-sectional, schematic view of a portion of the exemplary ice making assembly of FIG. 3 during an ice forming operation.

FIG. 6 provides a perspective view of an ice mold and an evaporator assembly according to an exemplary embodiment of the present subject matter.

FIG. 7 provides a bottom perspective view of the exemplary ice mold and evaporator assembly of FIG. 6 according to an exemplary embodiment of the present subject matter.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

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.

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”).

Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. For example, the approximating language may refer to being within a 10 percent margin.

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 simplified perspective view of ice making assembly 102. Generally, ice making appliance 100 includes a cabinet 104 (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 104 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 that includes a freezer chamber (e.g., a top mount refrigerator appliance, a bottom mount refrigerator appliance, a side-by-side style refrigerator appliance, etc.). 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 104 (e.g., at a top portion thereof). As would be understood, door 105 may selectively cover an opening defined by cabinet 104. For instance, door 105 may rotate on cabinet 104 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 (e.g., non-transitive 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 104. 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.

Generally, as shown in FIGS. 3 and 4, ice making appliance 100 includes a sealed refrigeration system 112 for executing a vapor compression cycle for cooling water within ice making appliance 100 (e.g., within freezer chamber 106). Sealed refrigeration 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 refrigeration system 112 may include additional components (e.g., one or more directional flow valves or an additional evaporator, compressor, expansion device, or condenser). Moreover, at least one component (e.g., evaporator 120) is provided in thermal communication (e.g., conductive thermal communication) with an ice mold or mold assembly 130 (FIG. 3) to cool mold assembly 130, such as during ice making operations. Optionally, evaporator 120 is mounted within freezer chamber 106.

Within sealed refrigeration 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 118 (e.g., a mechanical valve, capillary tube, electronic expansion valve, or other restriction device) 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 water and ice or air is produced and refrigerates ice making appliance 100 or freezer chamber 106. Thus, evaporator 120 is a heat exchanger which transfers heat from water or air in thermal communication with evaporator 120 to refrigerant flowing through evaporator 120.

Optionally, as described in more detail below, one or more directional valves may be provided (e.g., between compressor 114 and condenser 116) to selectively redirect refrigerant through a bypass line connecting the directional valve or valves to a point in the fluid circuit downstream from the expansion device 118 and upstream from the evaporator 120. In other words, the one or more directional valves may permit refrigerant to selectively bypass the condenser 116 and expansion device 120.

In additional or alternative embodiments, ice making appliance 100 further includes a supply valve 122 for regulating a flow of liquid water to ice making assembly 102. For example, supply valve 122 may be selectively adjustable between an open configuration and a closed configuration. In the open configuration, supply valve 122 permits a flow of liquid water to ice making assembly 102 (e.g., to a pump assembly 132 or a water basin 134 of ice making assembly 102). Conversely, in the closed configuration, supply valve 122 hinders the flow of liquid water to ice making assembly 102. However, it should be appreciated that certain exemplary embodiments require no supply valve at all.

In certain embodiments, ice making appliance 100 also includes a discrete chamber cooling system 124 (e.g., separate from sealed refrigeration system 112) to generally draw heat from within freezer chamber 106. For example, discrete chamber cooling system 124 may include a corresponding sealed refrigeration circuit (e.g., including a unique compressor, condenser, evaporator, and expansion device) or air handler (e.g., axial fan, centrifugal fan, etc.) configured to motivate a flow of chilled air within freezer chamber 106. According to an exemplary embodiment, a second evaporator may be tied into the chamber cooling system 124 or sealed cooling system 124.

Turning now to FIGS. 3 and 4, FIG. 4 provides a cross-sectional, schematic view of ice making assembly 102. As shown, ice making assembly 102 includes a mold assembly 130 that defines a mold cavity 136 within which an ice billet 138 may be formed. Optionally, a plurality of mold cavities 136 may be defined by mold assembly 130 and spaced apart from each other (e.g., perpendicular to the vertical direction V). One or more portions of sealed refrigeration system 112 may be in thermal communication with mold assembly 130. In particular, evaporator 120 may be placed on or in contact (e.g., conductive contact) with a portion of mold assembly 130. During use, evaporator 120 may selectively draw heat from mold cavity 136, as will be further described below. Moreover, a pump assembly 132 positioned below mold assembly 130 may selectively direct the flow of water into mold cavity 136. Generally, pump assembly 132 includes a circulation pump 140 and at least one nozzle 142 directed (e.g., vertically) toward mold cavity 136. In embodiments wherein multiple discrete mold cavities 136 are defined by mold assembly 130, pump assembly 132 may include a plurality of nozzles 142 or fluid pumps vertically aligned with the plurality mold cavities 136. For instance, each mold cavity 136 may be vertically aligned with a discrete nozzle 142.

In some embodiments, a water basin 134 is positioned below the ice mold (e.g., directly beneath mold cavity 136 along the vertical direction V). Water basin 134 includes a solid nonpermeable body and may define a vertical opening 145 and interior volume 146 in fluid communication with mold cavity 136. When assembled, fluids, such as excess water falling from mold cavity 136, may pass into interior volume 146 of water basin 134 through vertical opening 145. In certain embodiments, one or more portions of pump assembly 132 are positioned within water basin 134 (e.g., within interior volume 146). As an example, circulation pump 140 may be mounted within water basin 134 in fluid communication with interior volume 146. Thus, circulation pump 140 may selectively draw water from interior volume 146 (e.g., to be dispensed by spray nozzle 142). Nozzle 142 may extend (e.g., vertically) from circulation pump 140 through interior volume 146.

In optional embodiments, a guide ramp 148 is positioned between mold assembly 130 and water basin 134 along the vertical direction V. For example, guide ramp 148 may include a ramp surface that extends at a negative angle (e.g., relative to a horizontal direction) from a location beneath mold cavity 136 to another location spaced apart from water basin 134 (e.g., horizontally). In some such embodiments, guide ramp 148 extends to or terminates above an ice bin 150. Additionally or alternatively, guide ramp 148 may define a perforated portion 152 that is, for example, vertically aligned between mold cavity 136 and nozzle 142 or between mold cavity 136 and interior volume 146. One or more apertures are generally defined through guide ramp 148 at perforated portion 152. Fluids, such as water, may thus generally pass through perforated portion 152 of guide ramp 148 (e.g., along the vertical direction V between mold cavity 136 and interior volume 146). It should be appreciated that according to alternative embodiments, any suitable apparatus for separating falling liquid water from falling ice may be used.

As shown, ice bin 150 generally defines a storage volume 154 and may be positioned below mold assembly 130 and mold cavity 136. Ice billets 138 formed within mold cavity 136 may be expelled from mold assembly 130 and subsequently stored within storage volume 154 of ice bin 150 (e.g., within freezer chamber 106). In some such embodiments, ice bin 150 is positioned within freezer chamber 106 and horizontally spaced apart from water basin 134, pump assembly 132, or mold assembly 130. Guide ramp 148 may span the horizontal distance between mold assembly 130 and ice bin 150. As ice billets 138 descend or fall from mold cavity 136, the ice billets 138 may thus be motivated (e.g., by gravity) toward ice bin 150.

Turning now generally to FIGS. 4 and 5, exemplary ice forming operations of ice making assembly 102 will be described. As shown, mold assembly 130 is formed from discrete conductive ice mold 160 and insulation jacket 162. Generally, insulation jacket 162 extends downward from (e.g., directly from) conductive ice mold 160. For instance, insulation jacket 162 may be fixed to conductive ice mold 160 through one or more suitable adhesives or attachment fasteners (e.g., bolts, latches, mated prongs-channels, etc.) positioned or formed between conductive ice mold 160 and insulation jacket 162.

Together, conductive ice mold 160 and insulation jacket 162 may define mold cavity 136. For instance, conductive ice mold 160 may define an upper portion 136A of mold cavity 136 while insulation jacket 162 defines a lower portion 136B of mold cavity 136. Upper portion 136A of mold cavity 136 may extend between a nonpermeable top end 164 and an open bottom end 166. Additionally or alternatively, upper portion 136A of mold cavity 136 may be curved (e.g., hemispherical) in open fluid communication with lower portion 136B of mold cavity 136. Lower portion 136B of mold cavity 136 may be a vertically open passage that is aligned (e.g., in the vertical direction V) with upper portion 136A of mold cavity 136. Thus, mold cavity 136 may extend along the vertical direction between a mold opening 168 at a bottom portion or bottom surface 170 of insulation jacket 162 to top end 164 within conductive ice mold 160. In some such embodiments, mold cavity 136 defines a constant diameter or horizontal width from lower portion 136B to upper portion 136A. When assembled, fluids, such as water may pass to upper portion 136A of mold cavity 136 through lower portion 136B of mold cavity 136 (e.g., after flowing through the bottom opening defined by insulation jacket 162).

Conductive ice mold 160 and insulation jacket 162 are formed, at least in part, from two different materials. Conductive ice mold 160 is generally formed from a thermally conductive material (e.g., metal, such as copper, aluminum, or stainless steel, including alloys thereof) while insulation jacket 162 is generally formed from a thermally insulating material (e.g., insulating polymer, such as a synthetic silicone configured for use within subfreezing temperatures without significant deterioration). According to alternative embodiments, insulation jacket 162 may be formed using polyethylene terephthalate (PET) plastic or any other suitable material. In some embodiments, conductive ice mold 160 is formed from material having a greater amount of water surface adhesion than the material from which insulation jacket 162 is formed. Water freezing within mold cavity 136 may be prevented from extending horizontally along bottom surface 170 of insulation jacket 162.

Advantageously, an ice billet within mold cavity 136 may be prevented from mushrooming beyond the bounds of mold cavity 136. Moreover, if multiple mold cavities 136 are defined within mold assembly 130, ice making assembly 102 may advantageously prevent a connecting layer of ice from being formed along the bottom surface 170 of insulation jacket 162 between the separate mold cavities 136 (and ice billets therein). Further advantageously, the present embodiments may ensure an even heat distribution across an ice billet within mold cavity 136. Cracking of the ice billet or formation of a concave dimple at the bottom of the ice billet may thus be prevented.

In some embodiments, the unique materials of conductive ice mold 160 and insulation jacket 162 each extend to the surfaces defining upper portion 136A and lower portion 136B of mold cavity 136. In particular, a material having a relatively high water adhesion may define the bounds of upper portion 136A of mold cavity 136 while a material having a relatively low water adhesion defines the bounds of lower portion 136B of mold cavity 136. For instance, the surface of insulation jacket 162 defining the bounds of lower portion 136B of mold cavity 136 may be formed from an insulating polymer (e.g., silicone). The surface of conductive mold cavity 136 defining the bounds of upper portion 136A of mold cavity 136 may be formed from a thermally conductive metal (e.g., aluminum or copper). In some such embodiments, the thermally conductive metal of conductive ice mold 160 may extend along (e.g., the entirety of) of upper portion 136A.

Although an exemplary mold assembly 130 is described above, it should be appreciated that variations and modifications may be made to mold assembly 130 while remaining within the scope of the present subject matter. For example, the size, number, position, and geometry of mold cavities 136 may vary. In addition, according to alternative embodiments, an insulation film may extend along and define the bounds of upper portion 136A of mold cavity 136, e.g., may extend along an inner surface of conductive ice mold 160 at upper portion 136A of mold cavity 136. Indeed, aspects of the present subject matter may be modified and implemented in a different ice making apparatus or process while remaining within the scope of the present subject matter.

In some embodiments, one or more sensors are mounted on or within ice mold 160 or in other locations within ice making appliance 100. As an example, a temperature sensor 180 may be mounted adjacent to ice mold 160. Temperature sensor 180 may be electrically coupled to controller 110 and configured to detect the temperature at various locations within ice mold 160. Temperature sensor 180 may be formed as any suitable temperature detecting device, such as a thermocouple, thermistor, etc. Although temperature sensor 180 is illustrated as being mounted to ice mold 160, it should be appreciated that according to alternative embodiments, temperature sensor may be positioned at any other suitable location for providing data indicative of the temperature of the ice mold 160. For example, temperature sensor 180 may alternatively be mounted to a coil of evaporator 120 or at any other suitable location within ice making appliance 100.

As shown, controller 110 may be in communication (e.g., electrical communication) with one or more portions of ice making assembly 102. In some embodiments, controller 110 is in communication with one or more fluid pumps (e.g., circulation pump 140), compressor 114, flow regulating valves, etc. Controller 110 may be configured to initiate discrete ice making operations and ice release operations. For instance, controller 110 may alternate the fluid source spray to mold cavity 136 and a release or ice harvest process, which will be described in more detail below.

During ice making operations, controller 110 may initiate or direct pump assembly 132 to motivate an ice-building spray (e.g., as indicated at arrows 184) through nozzle 142 and into mold cavity 136 (e.g., through mold opening 168). Controller 110 may further direct sealed refrigeration system 112 (e.g., at compressor 114) (FIG. 3) to motivate refrigerant through evaporator 120 and draw heat from within mold cavity 136. As the water from the ice-building spray 184 strikes mold assembly 130 within mold cavity 136, a portion of the water may freeze in progressive layers from top end 164 to bottom end 166. Excess water (e.g., water within mold cavity 136 that does not freeze upon contact with mold assembly 130 or the frozen volume herein) and impurities within the ice-building spray 184 may fall from mold cavity 136 and, for example, to water basin 134.

Once ice billets 138 are formed within mold cavity 136, an ice release or harvest process may be performed in accordance with embodiments of the present subject matter. Specifically, referring again to FIG. 3, sealed system 112 may further include a bypass conduit 190 that is fluidly coupled to refrigeration loop or sealed system 112 for routing a portion of the flow of refrigerant around condenser 116. In this manner, by selectively regulating the amount of relatively hot refrigerant flow that exits compressor 114 and bypasses condenser 116, the temperature of the flow of refrigerant passing into evaporator 120 may be precisely regulated.

Specifically, according to the illustrated embodiment, bypass conduit 190 extends from a first junction 192 to a second junction 194 within sealed system 112. First junction 192 is located between compressor 114 and condenser 116, e.g., downstream of compressor 114 and upstream of condenser 116. By contrast, second junction 194 is located between condenser 116 and evaporator 120, e.g., downstream of condenser 116 and upstream of evaporator 120. Moreover, according to the illustrated embodiment, second junction 194 is also located downstream of expansion device 118, although second junction 194 could alternatively be positioned upstream of expansion device 118. When plumbed in this manner, bypass conduit 190 provides a pathway through which a portion of the flow of refrigerant may pass directly from compressor 114 to a location immediately upstream of evaporator 120 to increase the temperature of evaporator 120.

Notably, if substantially all of the flow of refrigerant were diverted from compressor 114 through bypass conduit 190 when ice mold 160 is still very cold (e.g., below 10° F. or 20° F.), the thermal shock experienced by ice billets 138 due to the sudden increase in evaporator temperature might cause ice billets 138 to crack. Therefore, controller 110 may implement methods for slowly regulating or precisely controlling the evaporator temperature to achieve the desired mold temperature profile and harvest release time to prevent the ice billets 138 from cracking.

In this regard, for example, bypass conduit 190 may be fluidly coupled to sealed system 112 using a flow regulating device 196. Specifically, flow regulating device 196 may be used to couple bypass conduit 190 to sealed system 112 at first junction 192. In general, flow regulating device 196 may be any device suitable for regulating a flow rate of refrigerant through bypass conduit 190. For example, according to an exemplary embodiment of the present subject matter, flow regulating device 196 is an electronic expansion device which may selectively divert a portion of the flow of refrigerant exiting compressor 114 into bypass conduit 190. According to still another embodiment, flow regulating device 196 may be a servomotor-controlled valve for regulating the flow of refrigerant through bypass conduit 190. According to still other embodiments, flow regulating device 196 may be a three-way valve mounted at first junction 192 or a solenoid-controlled valve operably coupled along bypass conduit 190.

According to exemplary embodiments of the present subject matter, controller 110 may initiate an ice release or harvest process to discharge ice billets 138 from mold cavities 136. Specifically, for example, controller 110 may first halt or prevent the ice-building spray 184 by de-energizing circulation pump 140. Next, controller 110 may regulate the operation of sealed system 112 to slowly increase a temperature of evaporator 120 and ice mold 160. Specifically, by increasing the temperature of evaporator 120, the mold temperature of ice mold 160 is also increased, thereby facilitating partial melting or release of ice billets 138 from mold cavities.

According to exemplary embodiments, controller 110 may be operably coupled to flow regulating device 196 for regulating a flow rate of the flow of refrigerant through bypass conduit 190. Specifically, according to an exemplary embodiment, controller 110 may be configured for obtaining a mold temperature of the mold body using temperature sensor 180. Although the term “mold temperature” is used herein, it should be appreciated that temperature sensor 180 may measure any suitable temperature within the ice making appliance 100 that is indicative of mold temperature and may be used to facilitate improved harvest of ice billets 138.

Controller 110 may further regulate the flow regulating device 196 to control the flow of refrigerant based in part on the measured mold temperature. For example, according to an exemplary embodiment, flow regulating device 196 may be regulated such that a rate of change of the mold temperature does not exceed a predetermined threshold rate. For example, this predetermined threshold rate may be any suitable rate of temperature change beyond which thermal expansion of ice billets 138 may lead to cracking. For example, according to an exemplary embodiment, the predetermined threshold rate may be approximately 1° F. per minute, about 2° F. per minute, about 3° F. per minute, or higher. According to exemplary embodiments, the predetermined threshold rate may be less than 10° F. per minute, less than 5° F. permanent, less than 2° F. per minute, or lower. According to alternative embodiments, any other suitable threshold rate may be used. In this manner, flow regulating device 196 may regulate the rate of temperature change of ice billets 138, thereby preventing cracking due to thermal expansion.

In general, the sealed system 112 and methods of operation described herein are intended to regulate a temperature change of ice billets 138 to prevent cracking due to thermal expansion. However, although specific control algorithms and system configurations are described, it should be appreciated that according to alternative embodiments variations and modifications may be made to such systems and methods while remaining within the scope of the present subject matter. For example, the exact plumbing of bypass conduit 190 may vary, the type or position of flow regulating device 196 may change, and different control methods may be used while remaining within scope of the present subject matter. In addition, depending on the size and shape of ice billets 138, the predetermined threshold rate and predetermined temperature threshold may be adjusted to prevent that particular set of ice billets 138 from cracking, or to otherwise facilitate an improved harvest procedure.

Referring now specifically to FIGS. 6 and 7, an exemplary ice mold 200 and evaporator assembly 202 that may be used with ice making appliance 100 will be described according to exemplary embodiments of the present subject matter. Specifically, for example, ice mold 200 may be used as mold assembly 130 and evaporator assembly 202 may be used as evaporator 120 of sealed cooling system 112. Although ice mold 200 and evaporator assembly 202 are described herein with respect to ice making appliance 100, it should be appreciated that ice mold 200 and evaporator assembly 202 may be used in any other suitable ice making application or appliance.

As illustrated, ice mold 200 defines one or more mold cavities 210 within which ice billets 138 may be formed. Specifically, according to the illustrated embodiment, ice mold 200 includes two identical mold cavities 210 that are generally gem-shaped. In this regard, for example, mold cavities 210 may have an octagonal cross-section when viewed in a horizontal plane. It should be appreciated that the number, size, and shape of mold cavities 210 are illustrated and described herein only for the purpose of explaining aspects of the present subject matter. As such, variations and modifications may be made to mold cavities 210 while remaining within scope the present subject matter.

In general, ice mold 200 may be formed from any suitable material and in any suitable manner that provides sufficient thermal conductivity to transfer heat to evaporator assembly 202 to facilitate the ice making process. According to an exemplary embodiment, ice mold 200 is formed from aluminum, an aluminum alloy, etc. According to still other embodiments, ice mold 200 may be formed from any other suitable material, such as copper, any other metal, or any other suitably rigid and thermally conductive material.

In addition, ice mold 200 may generally be formed from two or more separable pieces. These pieces may be joined during the ice making process and separated to simplify ice harvesting. For example, as illustrated, ice mold 200 is formed from a first portion 212 and a second portion 214. Moreover, first portion 212 and second portion 214 are illustrated as being mirror images of each other, e.g., having the same dimensions, geometry, and a mirrored configuration. As a result, ice mold 200 may define a seam 216 that passes directly through a center of ice mold 200 to define first portion 212 and second portion 214. Notably, it may be desirable that seam 216 passes through or around each of the plurality of mold cavities 210 to facilitate easy removal of ice billets 138 after formation. In this regard, ice making assembly 100 may include features or structures for facilitating the simple separation of first portion 212 and second portion 214 of ice mold 200 on completion of the ice formation process. It should be appreciated that the separation process may be implemented in conjunction with a harvesting process, e.g., using sealed cooling system 112 and flow regulating device 196 to warm ice mold 200 and release ice billets 138.

Although ice mold 200 is illustrated as being formed from first portion 212 and second portion 214 to define two mold cavities 210, it should be appreciated that any suitable number of mold portions and mold cavities 210 may be used according to alternative embodiments. For example, first portion 212 and second portion 214 may be elongated such that more than two mold cavities 210 are defined along a straight line. According still other embodiments, additional mold portions may be incorporated to define any suitable array of mold cavities 210 while maintaining the ability to separate the mold portions after formation of ice billets 138.

In addition, first portion 212 and second portion 214 are generally illustrated as being rectangular, e.g., having substantially flat sides 220. However, according to alternative embodiments, ice mold 200 may have any other suitable geometry or configuration and may include any other suitable features for improving structural rigidity, thermal conductivity, and/or the ice formation process in general. For example, according to aspects of the present subject matter, each of first portion 212 and second portion 214 may include features for improving the thermal coupling between evaporator assembly 202 and ice mold 200, e.g., to improve the thermal efficiency and thermal distribution of ice making assembly 100.

Specifically, referring still to FIGS. 6 and 7, ice mold 200 may generally define a plurality of recessed passages 230 that extend through first portion 212 and second portion 214 to at least partially surround mold cavities 210. Moreover, recessed passages 230 may generally be sized and configured for receiving evaporator conduit 232 of evaporator assembly 202. In this manner, the thermal coupling between evaporator assembly 202 and ice mold 200 may be improved such that the cooling capacity and temperature distribution of ice making assembly 100 is improved and the resulting ice billets 138 may be formed quickly and efficiently with minimal chance of cracking due to thermal gradients within ice mold 200 and ice billets 138. According to exemplary embodiments, evaporator conduit 232 may be copper tubing. However, it should be appreciated that any other suitable conduit having high thermal conductivity and structural rigidity may be used.

Specifically, evaporator conduit 232 may be positioned at least partially within recessed passages 230 to cool ice mold 200 and facilitate the ice formation process. According to exemplary embodiments, evaporator conduit 232 may be positioned in recessed passages 230 that are defined in any or every surface of ice mold 200 that is not defining a portion of mold cavities 210. In this regard, continuing the example from above where ice mold 200 is rectangular and has six sides 220, recessed passages 230 may be defined (and evaporator conduit 232 may be placed) in at least four of the six sides 220 of first portion 212 and second portion 214.

Moreover, it should be appreciated that recessed passages 230 and evaporator conduit 232 may be wrapped or positioned within ice mold 200 in any suitable manner or geometry. For example, according to the illustrated embodiment, recessed passages 230 and evaporator conduit 232 are serpentine to increase the thermal contact area. According to still other embodiments, recessed passages 230 and evaporator conduit 232 may be curvilinear, arcuate, undulating, zigzag, or any other suitable shape. Moreover, evaporator conduit 232 may be routed through the sides 220 of ice mold 200 in a sequential manner, such that each side 220 receives substantially equivalent cooling capacity of evaporator assembly 202.

Moreover, the width and depth of recessed passages 230 may be sized for receipt of evaporator conduit 232 to provide improved thermal communication with ice mold 200. In this regard, for example, recessed passages 230 may define an average depth 240 (e.g., as measured from a surface of side 220 to the deepest portion of recessed passages 230) that is greater than or equal to a conduit diameter 242 of evaporator conduit 232. In this manner, evaporator conduit 232 may be pressed into recessed passages 230 such that it is fully received within recessed passages and does not protrude from or is otherwise flush with flat side 220. Moreover, according to exemplary embodiments, the depth of recessed passages 230 may be variable depending on the proximity of recessed passages 230 to mold cavity 210. In this regard, for example, the depth of recessed passages 230 may be varied such that a distance between recessed passages 230 and mold cavity 210 is relatively constant. For example, as illustrated, the corners where sides 220 meet may define a curved passage with variable depth so that the evaporator conduit 232 may remain close to mold cavities 210 while also preventing kinking of evaporator conduit 232.

According to exemplary embodiments of the present subject matter, evaporator conduit 232 may be pressed into recessed passages 230 for increased thermal communication and heat conductivity therebetween. In this regard, for example, evaporator conduit 232 may initially be positioned within recessed passages 230, but there may be a slight airgap between evaporator conduit 230 and ice mold 200 at one or more locations. Therefore, evaporator conduit 230 may be further pressed into recessed passages 230 for improved contact and more efficient heat transfer. According to still other embodiments, this pressing process may result in a slight deformation of evaporator conduit 232, e.g., such that complete and continuous thermal contact is achieved between evaporator conduit 232 and ice mold.

In addition, the plurality of recessed passages may define a passage width 244 that is substantially equivalent to conduit diameter 242. In addition, the bottom of recessed passages 230 may be curved at the same radius as evaporator conduit 232 for improved thermal engagement between evaporator conduit 232 and ice mold 200. Other variations and modifications to the size and geometry of recessed passages 230 and evaporator conduit 232 may be used while remaining within the scope of the present subject matter. According still other embodiments, a thermally insulating cover or topping material may be positioned over evaporator conduit 232 after it is positioned within recessed passages 232, e.g., to improve the thermal coupling between evaporator assembly 202 and ice mold 200.

According to exemplary embodiments, evaporator assembly 202 may include a dedicated evaporator conduit for each portion of ice mold 200. Moreover, these portions may be connected in parallel such that each portion of ice mold 200 may receive substantially equal cooling capacity. Specifically, according to the illustrated embodiment, evaporator assembly 202 includes a first evaporator portion 250 that is mounted within first portion 212 and a second evaporator portion 252 that is mounted within second portion 214. It should be appreciated that any other suitable plumbing configuration of evaporator conduit 232 may be used while remaining within the scope of the present subject matter.

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. An ice making assembly comprising:

an ice mold defining a mold cavity, wherein the ice mold defines a plurality of recessed passages that at least partially surround the mold cavity;

a sealed refrigeration system comprising a condenser and an evaporator in serial flow communication with each other, the evaporator being positioned within the plurality of recessed passages to cool the ice mold; and

a pump assembly for urging an ice-building spray into the ice mold to form an ice billet.

2. The ice making assembly of claim 1, wherein the ice mold comprises a first portion and a second portion, the second portion being separable from the first portion.

3. The ice making assembly of claim 2, wherein the evaporator includes a first evaporator portion mounted within the first portion and a second evaporator portion mounted within the second portion, the first evaporator portion and the second evaporator portion being connected in parallel.

4. The ice making assembly of claim 2, wherein the first portion is a mirror image of the second portion.

5. The ice making assembly of claim 1, wherein the ice mold is substantially rectangular having six sides, and wherein the plurality of recessed passages is formed in at least four of the six sides of the ice mold.

6. The ice making assembly of claim 1, wherein the plurality of recessed passages defines a serpentine or zig-zag pattern through at least a portion of the ice mold.

7. The ice making assembly of claim 1, wherein the plurality of recessed passages defines an average depth that is greater than or equal to a conduit diameter of the evaporator.

8. The ice making assembly of claim 1, wherein a depth of the plurality of recessed passages is variable.

9. The ice making assembly of claim 1, wherein the plurality of recessed passages defines an average passage width that is substantially equivalent to a conduit diameter of the evaporator.

10. The ice making assembly of claim 1, wherein the evaporator comprises copper tubing.

11. The ice making assembly of claim 1, wherein the ice mold is formed from aluminum.

12. The ice making assembly of claim 1, wherein the ice mold defines a plurality of mold cavities.

13. The ice making assembly of claim 12, wherein a seam that divides a first portion and a second portion of the ice mold passes through each of the plurality of mold cavities.

14. The ice making assembly of claim 1, wherein the ice mold comprises more than two separable pieces.

15. A mold assembly for an ice making assembly, the mold assembly comprising:

an ice mold comprising a first portion and a second portion that are separable and define a mold cavity, wherein the ice mold defines a plurality of recessed passages that at least partially surround the mold cavity and are configured for receiving evaporator conduit.

16. The mold assembly of claim 15, wherein the evaporator conduit includes a first evaporator portion mounted within the first portion and a second evaporator portion mounted within the second portion, the first evaporator portion and the second evaporator portion being connected in parallel.

17. The mold assembly of claim 15, wherein the plurality of recessed passages defines an average depth that is greater than or equal to a conduit diameter of the evaporator conduit.

18. The mold assembly of claim 15, wherein a depth of the plurality of recessed passages is variable.

19. The mold assembly of claim 15, wherein the plurality of recessed passages defines an average passage width that is substantially equivalent to a conduit diameter of the evaporator conduit.

20. The mold assembly of claim 15, wherein the evaporator conduit comprises copper tubing and the ice mold is formed from aluminum.