FLOWER MOLD & HARVESTING MECHANISM FOR SPHERICAL ICE

Abstract

An ice-making appliance comprising a flexible mold having a plurality of interconnected ice-forming cavities, a single-fill cavity configuration configured to distribute water uniformly across the interconnected ice-forming cavities, a drive motor configured to rotate the flexible mold between an ice-making position and an ice-harvesting position, an ejection mechanism comprising at least one extraction pin positioned adjacent to the flexible mold, and a storage bin configured to collect ejected ice pieces.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. provisional application No. 63/766,112 filed March 3, 2025, the disclosure of which is hereby incorporated in its entirety by reference herein.

TECHNICAL FIELD

The present disclosure relates to a craft ice-making appliance having a mold and an associated ice storage.

BACKGROUND

Refrigeration and freezing appliances often include ice makers either in a fresh food compartment, an appliance door, or a freezer compartment to provide ice pieces for consumption. In order to create ice production, a low temperature must be supplied and maintained to freeze supplied water molecules into ice pieces. Ice pieces are typically made by distributing the water molecules into a mold and circulating freezing air across the mold and the water stored in the mold. Current ice makers produce ice that is opaque and fail to produce a craft ice product that is clear in appearance and slow to dissolve.

SUMMARY

The present disclosure sets forth a refrigerator having a craft ice-making appliance incorporating an innovative flower-mold design. The disclosed appliance features a flexible, interconnected mold structure capable of producing multiple craft ice pieces from a single water fill cycle. Unlike traditional ice makers that require multiple molds or complex mechanisms, aspects of the disclosure utilize a single-fill cavity with a flower-like flexible mold in a linear configuration. The mold allows for equal distribution of water into each cavity via a single filling tube, simplifying the ice-making process. The flexible material of the mold aids in the easy removal of ice, while its interconnected nature ensures uniform water distribution. The ice-making appliance further includes a single drive motor that secures the mold within a frame structure and rotates between an ice-making position and an ice-harvesting position. This setup ensures efficient and reliable ice production without the need for multiple moving components.

The present disclosure further sets forth aspects related to a craft ice-making appliance designed to produce clear ice spheres ranging from 1.5 to 4.5 inches in diameter, though other shapes and sizes are supported within the capabilities of the mold. The interconnected mold cavities are arranged in a configuration limited only by the freezer cavity footprint, allowing for optimal ice production. The flexible material of the mold enables efficient ice extraction using an ejection pin mechanism. The appliance incorporates an advanced freezing process using wire heaters strategically positioned around the mold, ensuring a top-to-bottom freezing pattern that promotes ice clarity exceeding 75%. Once the ice is formed, a plurality of mold heaters are activated and the mold rotates to an ejection position, where each cavity of the flexible mold splits open to release the craft ice into a storage bin. The ice storage system is designed for efficient organization and retrieval, incorporating features such as sloped bases, guide ramps, and diverters to facilitate a first-in, first-out ice usage system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of an exemplary refrigeration appliance;

FIG. 2 is a side perspective view of the refrigeration appliance with a cabinet structure removed;

FIG. 3 is a side view of the refrigeration appliance with the cabinet structure removed;

FIG. 4 is a front perspective view of a freezer liner;

FIG. 5 is a front perspective view of an ice maker assembly and a freezer air duct housing;

FIG. 6 is a perspective view of the ice maker assembly;

FIG. 7 is a detail view of an ice maker air diffusion plate having fins;

FIG. 8 is a detail view of an ice maker air diffusion plate having through holes;

FIG. 9 is a cross-sectional side view of the ice maker assembly;

FIG. 10 is a detail view of the ice-making assembly illustrating clear ice formation and harvesting heating elements;

FIG. 11 is an exploded partial view of an ice molding and ejection assembly;

FIG. 12A is a perspective view of a flower mold of the ice molding and ejection assembly;

FIG. 12B is a perspective cross-sectional view of the flower mold taken along a vertical longitudinal axis of the flower mold;

FIG. 12C is a side view of the flower mold;

FIG. 12D is a side cross-sectional view of the flower mold taken along the vertical longitudinal axis of the flower mold;

FIG. 13 is a partial detail view of the ice maker with various elements removed for illustrative purposes;

FIG. 14 is a perspective detail view of a first side of an ice-making mold and casings assembly;

FIG. 15 is a perspective detail view of a second side of the ice-making mold and casings assembly;

FIG. 16 is a perspective detail view of the ice-making mold and casings assembly and an ice piece inventory bale arm;

FIG. 17 is a cross-sectional view of an ice maker illustrating an ice sphere hopper diverter;

FIG. 18 is a front perspective view of an ice storage bin;

FIG. 19 is a top perspective view of the ice storage bin;

FIG. 20 is a rear perspective cross-sectional view of the ice maker assembly and ice storage bin, illustrating ice spheres stored within the ice storage bin;

FIG. 21 is top side cross-sectional view of the ice maker assembly, illustrating ice spheres partially ejected from the flower mold;

FIG. 22 is a front perspective cross-sectional view of the ice maker assembly;

FIG. 23 is a perspective top view of an ice maker having a top fill flower mold and a vertical ejection system, where a cover has been removed from the ice maker for illustrative purposes;

FIG. 24 is a top perspective view of the top fill flower mold illustrating a water trough and water flow channels;

FIG. 25 is a side perspective cross-sectional view of the ice maker having the top fill flower mold and vertical ejection system, illustrating an ice sphere ejection path and a craft ice deflector guide;

FIG. 26 is a top perspective view of an ice maker having a bottom fill flower mold and a vertical ejection system, with the ice maker having a top cover attached thereto;

FIG. 27 is a side cross-sectional view of the bottom fill flower mold ice maker illustrating a single water supply that is connected to the three flower molds with connecting tubes;

FIG. 28 is a side cross-sectional view of the ice maker having the bottom fill flower mold and the vertical ejection system, illustrating an ice sphere ejection path and a craft ice deflector guide;

FIG. 29A is a top perspective view of an ice maker storage bin having organization features;

FIG. 29B is partial top perspective view of the ice maker storage bin of FIG. 29A;

FIG. 30A is a partially exploded perspective view of the ice maker of FIG. 23 having the top fill flower mold and vertical ejection system, illustrating the ice spheres dropping down into the ice storage bin;

FIG. 30B is a detail view of the ice storage bin of FIG. 30A;

FIG. 31A is a perspective view of the ice maker of FIG. 23 having the top fill flower mold and vertical ejection system, with the ice storage bin detached to illustrate placement of the ice spheres after ejection into an ice bin ramp;

FIG. 31B is a perspective view of the ice bin ramp of FIG. 31A;

FIG. 31C is a perspective view of the ice storage bin of FIG. 31A; and

FIG. 32 is a flowchart illustrating a method of forming ice.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures may be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the disclosure as oriented in FIG. 1. Unless stated otherwise, the term “front” shall refer to the surface of the element closer to an intended viewer, and the term “rear” shall refer to the surface of the element further from the intended viewer. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

The terms “including,” “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by “comprises a . . .” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

Aspects of the disclosure herein relate to a craft ice-making appliance having a flower mold design. Merely by way of non-limiting example, the mold illustrated is a spherical ice mold for producing ice pieces shaped like spheres where multiple clear ice spheres are produced from a single mold having a plurality of interconnected craft ice producing cavities. Unlike traditional ice makers that rely on multiple molds or complex mechanisms, aspects of the disclosure include a unique, single-fill cavity, flower-like flexible mold configured in a linear configuration, where a single water fill extends into each cavity of the single mold design.

This design simplifies the ice-making process, allowing equal filling of multiple craft ice producing cavities through a single filling tube, filled from the top of the mold. Additionally, and as will be discussed as other aspects of the disclosure, equal filling may also be achieved through a single fill tube supply at the top of the mold that fills each cavity at the base of the mold for bottom filling. Additionally, the craft ice-making appliance includes and operates using a single drive motor configured to clamp or secure the mold in a frame structure and ultimately in an ice-making configuration and then rotating to an ice harvesting configuration.

It should be understood that the discussion herein references craft ice in the shape of a sphere that is substantially between 2 and 3 inches in diameter, the use of other shapes may be discussed as well as other dimensions and the invention is in no way limited by the use of these specific dimensions but rather a range of 1.75 inches to 4.5 inches at the widest point, which is consistent with the opening of a typical drink vessel opening. More specifically, aspects of the unique mold design may include a single interconnected cavity capable of producing a plurality of craft ice pieces, including but not limited to a spherical ice ball, or other known shapes of craft ice pieces (i.e., cylinder, pill, and cube) simultaneously. As illustrated and described below, the mold may include at least two interconnected cavities. However, the number of cavities is merely limited by the footprint within the freezer cavity and may also vary based on the desired size and shape of the craft ice product desired. The mold may be constructed from a flexible material that is able to be manipulated to eject the ice piece while being able to reassume the desired and predetermined shape of the specific craft ice shape being produced. The distinctive flower-like shape, illustrated in the figures combined with the flexible mold material facilitates easy ice removal. The interconnected design of the mold ensures even water distribution, while its flexible nature allows ice to be harvested using an extraction pin and the drive motor.

Referring to the illustrations, FIGS. 1-3 show a refrigerator appliance 10 for housing an ice maker 100 according to aspects of the disclosure. The refrigerator includes an outer cabinet structure 12 having a rear wall 14 and surrounding a liner structure 16 with an insulation space there between. The liner structure 16 is configured to define a plurality of cavities for storing fresh food and sealed by a plurality of doors operable to open and close thereby providing access to cavities. More specifically, the liner structure 16 may include a refrigerator liner 18, a drawer liner 20, and a freezer liner 22. The refrigerator liner 18 defining a fresh food cavity 24 and enclosed by at least one fresh food cavity door 26. The drawer liner 20 defining a drawer cavity 34 that may be either a fresh food cavity or a freezer cavity and enclosed by at least one drawer face or drawer door 32. The freezer liner 22 defining a freezer cavity 28 and enclosed by a freezer door 30. As illustrated and discussed further, herein and by non-limiting example, the ice maker 100 is positioned in the freezer cavity 28 and attached to an upper liner wall of the freezer liner 22.

However, it should be understood that the ice maker 100 may also be positioned in a housing within the fresh food cavity 24 and may be connected to an access opening of an ice/water dispenser 36 extending through the at least one fresh food cavity door 26. Alternatively, the ice maker 100 may also be configured within the drawer cavity 34 or adjacent there too, where the drawer cavity 34 stores the finished craft ice product. Turning to FIG. 2, the ice maker 100 is fluidly connected through an ice maker water inlet or ice maker water supply line 52 positioned in an ice maker water supply tube housing 50 to a refrigerator water supply inlet line 38 at an ice maker water supply housing 40 positioned on the rear wall 14. The ice maker 100 is also fluidly connected to a refrigeration system 42 through an air supply duct housing 44. The refrigeration system 42 converts warm air into cooled air while the air supply duct housing 44 includes at least a fan to push cold air into the ice maker 100 to convert the water supply into a solid ice product, which will be discussed in greater detail below. Additionally, referring to FIG. 3, it is clear and by non-limiting example that the structure presented shows the ice maker water supply tube housing 50 extending from the top of the freezer liner 22, extending through the insulation space and terminating at the ice maker water supply housing 40 on the rear wall 14.

FIG. 4 illustrates a more detailed view of the freezer liner 22 and more specifically the freezer cavity 28 housing the ice maker 100 within. A freezer pullout tray 72 is positioned within the freezer cavity 28 and supports an ice storage hopper or ice storage bin 70, which is positioned beneath the ice maker 100. The ice maker 100 has a main housing 104, an electronics and drive motor housing 106 positioned on the front of the main housing 104 and covering an actuator, a drive, or drive motor 110 (see FIG. 13), associated electronics 108 (see FIG. 13), and a gear assembly 112 (see FIG. 13). The freezer pullout tray 72 is illustrated as defining a notch 76, which exposes the ice storage bin 70 and an ice bin handle 78. FIG. 4 further illustrates greater detail of the ice maker water supply tube housing 50 extending from the ice maker water supply housing 40 on the rear wall 14 and an ice maker water inlet housing 48 covering an ice maker water inlet 54 that is fluidly connected to the refrigerator water supply inlet line 38 for supplying an ice- making water liquid to a flexible mold 134 for making craft ice, such as craft ice spheres 120. The flexible mold 134 may be flower-shaped.

Water filling is one of multiple aspects disclosed herein related to making a substantially clear craft ice piece. Filling the flexible mold with the required amount of water may be controlled either by sensors or timers based on predetermined volume and fill rate inputs within a controller 105. The controller 105 may be included in the associated electronics 108. More specifically, the water filling step includes rotating the mold to a fixed and closed position where the ice-making mold is positioned in an upper and lower support to provide rigidity to the flexible mold when filling. The mold is filled with a predetermined and measured volume of water. Water is introduced through a single filling tube fluidly connected to a water supply extending from a back wall of the refrigerator housing extending through the refrigerator insulation and into a conduit extending from the back wall and into a top of the freezer liner. The conduit is further connected to a water inlet on top of an ice-making housing and extending through an ice-making supply air duct. The inlet directs the water into a first ice-making cavity to begin filling the first cavity. Due to the interconnected design of the mold, water spreads evenly to the other ice-making cavities simultaneously, ensuring uniform filling across each mold. It should be understood that the fill process may be controlled by a specific predetermined volume measured by a flowmeter, a time frequency flow controller, or a level sensor 107 may be used to stop the water filling step, each of which may be utilized separately or in combination to prevent overflowing the molds.

Water is introduced through the ice maker water supply line 52, into the ice maker water inlet 54 and at least a first ice-making cavity 138 of the flexible mold 134 (see FIGS. 11- 12D), which may be accomplished by opening one or more valves. The water fills a base of the first ice-making cavity 138 and is distributed evenly to a second ice-making cavity 140 and a third ice-making cavity 142 via water distribution channels or water distribution connecting tubes 160 (see FIGS. 11- 12D). The water distribution connecting tubes 160 extend between each of the cavities and once the base of the third ice-making cavity 142 is filled, the water will move through the water distribution connecting tubes 160 to fill a fourth ice-making cavity 144 until the cavities (e.g., the first ice-making cavity 138, the second ice-making cavity 140, the third ice-making cavity 142, and the fourth ice-making cavity 144) are all filled with the desired volume of water. The water distribution connecting tubes 160 may be defined by and within the flexible mold 134. The water distribution connecting tubes 160 may fluidly interconnect ice-making cavities 136 that are defined by and within the flexible mold 134.

While illustrated as one controller, the controller 105 may be part of a larger control system and may be controlled by various other controllers throughout the refrigerator appliance 10. It should therefore be understood that the controller 105 and one or more other controllers can collectively be referred to as a “controller” that controls various actuators in response to signals from various sensors to control functions the refrigerator appliance 10. The controller 105 may include a microprocessor or central processing unit (CPU) in communication with various types of computer readable storage devices or media (e.g., a non-transitory computer readable medium having instructions stored thereon). Computer readable storage devices or media may include volatile and nonvolatile storage in read-only memory (ROM), random-access memory (RAM), and keep-alive memory (KAM), for example. KAM is a persistent or non-volatile memory that may be used to store various operating variables while the CPU is powered down. Computer-readable storage devices or media may be implemented using any of a number of known memory devices such as PROMs (programmable read-only memory), EPROMs (electrically PROM), EEPROMs (electrically erasable PROM), flash memory, or any other electric, magnetic, optical, or combination memory devices capable of storing data, some of which represent executable instructions, used by the controller 105 in controlling the refrigerator appliance.

Control logic or functions performed by the controller 105 may be represented by flow charts or similar diagrams in one or more figures. These figures provide representative control strategies and/or logic that may be implemented using one or more processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. As such, various steps or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Although not always explicitly illustrated, one of ordinary skill in the art will recognize that one or more of the illustrated steps or functions may be repeatedly performed depending upon the particular processing strategy being used. Similarly, the order of processing is not necessarily required to achieve the features and advantages described herein, but is provided for ease of illustration and description. The control logic may be implemented primarily in software executed by a microprocessor-based controller, such as controller 105. Of course, the control logic may be implemented in software, hardware, or a combination of software and hardware in one or more controllers depending upon the particular application. When implemented in software, the control logic may be provided in one or more computer-readable storage devices or media having stored data representing code or instructions executed by a computer to control the refrigerator appliance 10 or its subsystems. The computer-readable storage devices or media may include one or more of a number of known physical devices which utilize electric, magnetic, and/or optical storage to keep executable instructions and associated calibration information, operating variables, and the like.

FIGS. 5-8 illustrate the ice maker 100 in greater detail. More specifically, FIG. 5 illustrates a connection between the air supply duct housing 44 and a two-piece ice-making air supply duct 46 having an air supply duct top cover 58 and an air diffusion bottom cover 60. As previously discussed, the air supply duct housing 44 is fluidly connected to the refrigeration system 42 and is configured to distribute cold air from the refrigeration system 42 to the ice maker 100 through the air supply duct housing 44. Additionally, and as illustrated in greater detail in FIG. 6, the ice maker water inlet 54 is positioned on and extends through the air supply duct top cover 58. The ice maker water inlet 54 further includes a water funnel 56 positioned around the ice maker water inlet 54 that is configured to further direct water into the flexible mold 134. The illustrations of both FIGS. 5 and 6 show the positioning of the ice storage bin 70 relative to the main housing 104. The ice storage bin 70 defines an ice bin cavity 80 for receiving and storing an ice product and an ice bin cavity diverter 82 that is configured to direct the ice product within the ice bin cavity 80 for organized storage. An ice maker bail arm 84 and connecting bail arm flap 86 are also illustrated above the ice storage bin 70 to stop an ice-making process if the ice storage bin 70 is full of ice product or to start the ice-making process if the ice storage bin 70 is ready to be refilled.

Turning to FIGS. 7-8, illustrate further aspects of the air diffusion bottom cover 60. By non-limiting example, an air diffusion plate bottom cover 60a is illustrated in FIG. 7 as having a plurality of air diffusion fins 62 configured along a substantially planar base of the bottom cover 60a. The air diffusion fins 62 define a plurality of channels or through holes configured or aligned linearly along a longitudinal center line and extending out perpendicularly from longitudinal center line on the planar base. As a non-limiting example, the air diffusion fins 62 are illustrated as a vent on both sides of the ice maker water inlet 54 and above a top casing 130 that covers the flexible mold 134. The air diffusion fins 62 allow cooled air from the refrigeration system 42 to be directed to a plurality of ice-making cavities 136 defined by the flexible mold 134 positioned beneath the bottom cover 60a. The ice-making cavities 136 may include the first ice-making cavity 138, the second ice-making cavity 140, the third ice-making cavity 142, and the fourth ice-making cavity 144. It should be understood that the air diffusion fins 62 may vary in size such that the size may increase as the distance from an entrance of the ice-making air supply duct 46 is greater, for example the air diffusion fins 62 at the entrance side may be smaller as compared to the air diffusion fins 62 at an opposite end, which is farthest away from the air supply entrance. The varying size of the air diffusion fins 62 may be predetermined to allow an equal amount of air flow across the plurality of ice-making cavities 136 during the ice-making process to prevent uneven cooling across the ice-making cavities 136.

Another aspect and non-limiting example of the air diffusion bottom cover 60 is illustrated in FIG. 8 as an air diffusion plate 60b that is configured with a plurality of air diffusion rings 64, which may be circular in shape. Each air diffusion ring 64 positioned above and corresponding to one of the plurality of ice-making cavities 136, with the ice maker water inlet 54 extending through at least one of the air diffusion rings 64. The air diffusion rings 64 each including a plurality of air diffusion through holes 66 configured to regulate and distribute the freezer air from the refrigeration system 42. As illustrated, the air diffusion ring 64 closest to the air supply side includes fewer air diffusion through holes 66, which are smaller in circumference or diameter when compared to the air diffusion through holes 66 associated with the other air diffusion rings 64. The air diffusion through holes 66 may increase circumference or diameter, and may increase in quantity across the air diffusion rings 64 extending from the air diffusion ring 64 closest to the air supply side to the air diffusion ring 64 furthest from the air supply side. Additionally, and like the air diffusion fins 62, discussed above, the diffusion through holes 66 are configured to distribute a substantially balanced air flow across each of the plurality of ice-making cavities 136 to promote even and thorough cooling during the ice-making process. FIG. 8 also illustrates a rear housing wall 68 that is configured to enclose a rear of the main housing 104 and to further retain the cold freezer air around the flexible molds 134.

Turning to FIGS. 9-10, a more detailed aspect of the ice maker 100 is illustrated. More specifically, FIG. 9 is a cross-sectional view with the long side of the ice maker 100 removed on a left side relative to a front of the ice maker 100, illustrating the layout of the air supply duct top cover 58, the air diffusion bottom cover 60, the ice maker water inlet 54, and associated water funnel 56 extending therethrough and as positioned over the ice molding and ejection assembly 128. Here, the ice molding and ejection assembly 128 is in a closed or ice-making position and is ready for water to fill the plurality of ice-making cavities 136 to start the ice-making process. With reference to FIG. 10, a cross-sectional view of one of the plurality of ice-making cavities 136 is illustrated. The cross-section in FIG. 10 is taken along a vertical axis and is perpendicular to the longitudinal section illustrated in FIG. 9. The electronics and drive motor housing 106, electronics 108, drive motor 110, and gear assembly 112 are sectioned off, along with a portion of the ice molding and ejection assembly 128. FIG. 10, illustrates the water filling process as being completed while the cold air is being directed to the ice maker 100 to form craft ice pieces, which may be craft ice spheres 120. It should be understood, however, that the craft ice pieces may have any desirable shape, including but not limited to spherical shapes.

Producing clear ice requires a unidirectional freezing process to push air bubbles toward the bottom of the ice. This process must occur slowly, as the diffusion of air in water is inherently slow and the need for unidirectional freezing exists. To promote this, a plurality of heaters 170, which may be wire heaters, are positioned around the mold to help control and regulate the freezing direction. By non-limiting example FIG. 10 illustrates the use of a top heater 172 positioned within a cavity on the top casing 130, a middle heater 174 positioned in the bottom casing 146 adjacent a fixation frame 132, and a bottom heater 176 positioned in a bottom casing 146 below the middle heater 174 and adjacent mold contours 158 positioned at a base of the flexible mold 134. These heaters 170 are positioned adjacent to and around each ice-making cavity 136 individually, such that each cavity includes dedicated heaters 170 positioned around the outside circumferences of the flexible mold 134 and may be directly in contact with and touching the flexible mold 134 outer surface. Operationally, freezing starts with all heaters 170 activated and by non-limiting example, the heaters 170 may be activated sequentially where the top heater 172 is turned off first, followed by the middle heater 174, and then the bottom heater 176. This sequence promotes top-to-bottom freezing, achieving ice clarity levels exceeding 75%. As discussed above, sensors may be used to monitor the temperature of the mold to ensure complete freezing of each craft ice sphere 120 and that the craft ice spheres 120 are ready for consumption to initiate the ice harvesting step.

The components associated with the ice-making process are by non-limiting examples illustrated generally in FIGS. 11-12C. FIG. 11 illustrates an exploded view in a stacked formation layout of how the ice molding and ejection assembly 128 elements are positioned relative to each other. The main housing 104, electronics and drive motor housing 106, electronics 108, drive motor 110, and gear assembly 112 have been removed to focus on the ice molding components. Here you can see the top casing 130, the fixation frame 132, flexible mold 134, bottom casing 146, and ejectors or ejection pins 152. The top casing 130 and the bottom casing 146 are configured to enclose and provide rigid support to the flexible mold 134 as well as provide a housing for the heaters 170. The fixation frame 132 is configured to secure the flexible mold 134 to the bottom casing 146 by encasing a mold mounting lip 162 that extends around an outer periphery at a centerline of the flexible mold 134. The fixation frame 132 further includes a plurality of fasteners or fixation tabs 164 protruding from a bottom surface of the fixation frame 132. The fixation tabs 164 are configured to extend through a plurality of bottom casing mounting holes 156 positioned around the mold mounting lip 162 and into a corresponding plurality of engagement holes 166 configured around the bottom casing 146. This allows the fixation frame 132 to secure the flexible mold 134 to the bottom casing 146 and allow the assembly to stay in place when the bottom casing 146 is rotated to an ejection position, away from the top casing 130. The top casing 130 includes channels 168 that are configured to receive slit protrusions 178. The slit protrusions 178 are configured on a top half of the flexible mold 134 and allow for the mold to separate and spread or split open at a mold slit 154, similar to a flower opening, during the ejection step, which will be discussed in greater detail below. Ejection pins 152 are mounted on a wall of the main housing 104 and include concave ends 180 that corresponds to mold contours 158 positioned at the base of each of the plurality of ice-making cavities 136.

With specific reference to the aspects of the flexible mold 134 illustrated in FIGS. 12A-12D, the plurality of ice-making cavities 136 are shown as a first ice-making cavity 138, a second ice-making cavity 140, a third ice-making cavity 142, and a fourth ice-making cavity 144, all being defined by a single flexible mold (e.g., flexible mold 134) and interconnected by the mold mounting lip 162. The mold mounting lip 162 may be horizontally positioned and planar, and may extend along a centerline of the flexible mold 134. The mold mounting lip 162 supports the flexible mold 134 and is sandwiched between the fixation frame 132 and the bottom casing 146. The flexible mold 134 also includes vertical webbing 161 connecting the mold slits 154. The flexible mold 134 is interconnected fluidly through water distribution connecting tubes 160 that, as discussed previously, fluidly and physically connect each ice-making cavity 136 together along with the vertical webbing 161 positioned above the water distribution connecting tubes 160. Specific reference is drawn to FIG. 12B where the image is sectioned along a longitudinal center, which is also on the same plane or line as the mold slits 154 as the mold slits 154 extend along the vertical webbing 161, which allows the mold to open and close to eject the craft ice spheres 120, which may be an ice sphere. Additionally, with reference to FIG. 12D, the interior of the mold illustrates the mold contours 158 positioned at the base of the flexible mold 134. These mold contours 158 may aid in locating the ejection pins 152 and allow the flexible mold 134 to return back to its predetermined or original shape after ejection of the ice and disengagement from the ejection pins 152. Stated in other terms, the flexible mold 134 is configured to deform in response to engagement with the ejection pins 152 and return to a non-deformed shape or non-deformed position in response to disengagement with the ejection pins 152. The mold contours 158 may also provide expansion points for the craft ice spheres 120 to expand into during the freezing process. The mold contours 158 may be regions of the flexible mold 134 that protrude into the flexible mold 134 when engaged by corresponding ejection pins 152. The mold contours 158 may also expand outward during the freezing process to ensure the craft ice spheres 120 are uniformly spherical.

Turning to FIG. 13 an aspect of the ice molding and ejection assembly 128 is illustrated. Specifically, a compact arrangement of the electronics 108, drive motor 110, and gear assembly 112 positioned at a front of the ice maker 100. The electronics 108 may be configured to receive a signal from the refrigerator appliance 10 to call for ice, which in turn will open a water supply valve (not illustrated) to supply water through the ice maker water supply line 52, as discussed above. Once a full signal is received, the electronics will close the water supply valve and then activate the heaters 170 and a valve within either its ice-making air supply duct 46 or the air supply duct housing 44 to supply freezing air across the flexible mold 134 and the plurality of ice-making cavities 136. Once the electronics 108 receives an ice complete signal the drive motor 110 is activated to rotate the bottom casing 146 and attached flexible mold 134 to engage the concave ends 180 of the ejection pins 152 with the mold contours 158 on the bottom of the flexible mold 134. By non-limiting example, rotation is conducted by the drive motor 110 rotating a driving gear 116, to rotate a lever gear 114, which includes a shaft 118 extending therethrough in an opening direction. The shaft 118 not only extends through the lever gear 114, but also extends into and is keyed to a set of bottom casing shaft tabs 148 and is supported by mold support 150 extending from at least one of the main housing 104, and the top casing 130. A set of bearings or bushings may be used at rotation point between the bottom casing shaft tabs 148 and the mold support 150 to help reduce friction and aid in the ease of rotation.

FIGS. 14-16 illustrate additional details of the bottom casing 146 in the post ejection position. FIGS. 14-16 also illustrate the ice molding and ejection assembly 128 in an open or ice-harvesting position or ice-ejection position where the craft ice spheres 120 may be ejected from the flexible mold 134 via the ejection pins 152. These illustrations show the shaft 118 extending the length of the top casing 130 and the bottom casing 146 while also illustrating the detail of the flexible mold 134 positioned within the bottom casing 146. Here you can see the plurality of ice-making cavities 136 in a first ice-making cavity 138, a second ice-making cavity 140, a third ice-making cavity 142 and a fourth ice-making cavity 144 configuration. Turning back to FIG. 13 and forward to FIG. 16 the ice maker bail arm 84 is illustrated having a bail arm flap 86, a bail arm contact arm 88, and a bail arm cross support 90. The ice maker bail arm 84 engages and is rotatably supported by the main housing 104. The bail arm flap 86 and the bail arm cross support are configured to contact the craft ice spheres 120 after it is ejected from the flexible mold 134 and dropped into the ice storage bin 70, which will be discussed in greater detail below.

Additionally, it should be understood that during the ice harvesting step, and once the water inside the flexible mold 134 is completely frozen, the craft ice spheres 120 must be harvested in a way so as not to damage the flexible mold 134 as the craft ice spheres 120 may adhere firmly to the inside of the plurality of ice-making cavities 136. Thus, to aid in the removal, the heaters 170 may be briefly activated by the electronics 108 to melt a thin layer of ice at a mold interface, facilitating smoother ice release. This melt process allows for easier mechanical extraction when the ejection pins 152 push against the mold contours 158 forcing the craft ice spheres 120 against the mold slits 154 and out of the flexible mold 134, which then drop into the ice storage bin 70. It should be understood that the gear assembly 112 controls the movement and rotation and provides a sufficient torque to perform the ice ejection or extraction from the flexible mold 134. Once the craft ice spheres 120 are ejected, the electronics 108 may receive a signal to operate the drive motor 110 to rotate in an opposite or reverse direction to move the bottom casing 146 to a closed or ice-making position.

Aspects discussed above demonstrate that after harvesting the craft ice spheres 120 from the flexible mold 134, the craft ice spheres 120 are directed to the ice storage bin 70 positioned beneath the ice maker 100. As seen in FIGS. 17-22, maneuvering the craft ice spheres 120 into the ice storage bin 70 may be accomplished by directly ejecting the craft ice spheres 120 into the ice bin cavity 80 using a guide rim 94, a guide ramp 96, and a guide hopper 98 (discussed in greater detail below) either individually or in combination. The guide rim 94 may also be referred to as an ice bin housing positioned around a top of the ice bin cavity 80 and configured to direct the craft ice spheres 120 to a central location within the ice storage bin 70. The guide ramp 96 is positioned beneath the ejection area and includes a slope. The guide ramp 96 is configured to catch the craft ice spheres 120 as they are ejected, assembling them in a single file line directing them into the ice bin cavity 80 at a repeatable position. Each of these solutions may be integrated as part of the ice storage bin 70, integrated with the main housing 104, and may be a separate piece that is positioned during assembly of the ice maker 100 or any combination.

To optimize storage, the craft ice spheres 120 are initially deposited at or near the back of the ice storage bin 70 when the guide ramp 96 and guide hopper 98 are used, and along the side when the guide rim 94 alone is used or when a free-falling for first-in, first-out consumption by a user, which helps to ensure that older ice is used before newly produced spheres. To aid in this the ice storage bin 70 may include the ice bin cavity diverter 82, a ramp 74, and a curved base 222 (discussed in greater detail below) to direct the craft ice spheres 120 to a central or linear path for removal by a user. The ice bin cavity diverter 82 may be used to separate and direct the craft ice spheres 120 to keep them organized and in line for removal. Additionally, the curved base 222 may be used to optimize and organize the storage of the craft ice spheres 120 keeping them easily accessible in the first-in, first-out manner for users.

Referring to FIGS. 18-22 the sloped base in the ice bin cavity 80 is visible showing how if the craft ice spheres 120 are released on the left side then the slope allows the craft ice spheres 120 to move to a flat area where a consumer can easily access the craft ice spheres 120 for consumption. As discussed above, the ice bin cavity diverter 82 is configured on various locations on the ice storage bin base. By non-limiting example, there may be a plurality of ice bin cavity diverters 82 positioned to align with the plurality of ice-making cavities 136 on the flexible mold 134. This arrangement allows the craft ice spheres 120 to drop down in a substantially linear fashion and stay aligned as they roll down the slope for storage in the ice bin cavity 80. With reference to FIGS. 21 and 22, the craft ice spheres 120 are positioned as they are ejected from the flexible mold 134 as they are dropping down for ice storage in the ice storage bin 70.

Turning now to FIG. 23, which illustrates alternative aspects of the disclosure with an ice maker 200 configured in a substantially square arrangement. Here, a non-limiting example is disclosed as ice maker 200 including a main housing 204 base housing two rows of flexible molds 234 separated by an ice chute 208 for depositing craft ice spheres 120 into an ice storage bin 270 (see FIG. 30A). The main housing 204 includes an actuator, a drive, a drive motor 210 positioned on and extending at least partially through an outer side wall. The drive motor 210 is rotatably coupled to a fixture 235 that forms part of an ejection mechanism by a shaft 218 extending from a gear assembly 212 and through an outer wall of the main housing 204. Aspects of each flexible mold 234 includes a top fill water inlet 214, that positioned on the top of the flexible mold 234, for introducing water to a plurality of ice-making cavities 236 (FIG. 24) that are defined by and within the flexible mold 234.

The water inlet 214 includes a sloped bottom surface 216 for directing water to a water fill channel 260 connected thereto. The water fill channel 260 may be in the form of a trough with an open top. The water inlet 214 and water fill channel 260 may correspond to a water delivery system that simultaneously directs or delivers water to the ice-making cavities 236 and evenly distributes water within the ice-making cavities 236. The water fill channel 260 extends from the water inlet 214 to mold cavity openings 262 for transferring water to each of the plurality of ice-making cavities 236. It should be understood that the two banks of flexible molds 234 and their corresponding elements may be mirror images of each other and can be configured as any number of cavities, meaning you could have at least one flexible mold 234, and a plurality of flexible molds 234 on each, thus the design allows for multiple configurations and the number of flexible molds 234 on each side is dependent on the footprint of the desired ice maker 200.

Merely by way of non-limiting example, FIG. 24 illustrates that the plurality of ice-making cavities 236 may be identified as a first ice-making cavity 238, a second ice-making cavity 240, and a third ice-making cavity 242 and by no way is the order at which each is described or labeled considered to be fixed in arrangement. Here, the water inlet 214 is connected to the water fill channel 260 on a first side to fill the first ice-making cavity 238 and on the second side to fill the second ice-making cavity 240. Once the first ice-making cavity 238 and the second ice-making cavity 240 are filled, water will flow to the third ice-making cavity 242 via the fill channel 260. Thus, by non-limiting example, the water fill channel 260 is a single channel having multiple branches to fill each of the plurality of ice-making cavities 236 with water for making the craft ice spheres 120. This arrangement allows for the first ice-making cavity 238 and second ice-making cavity 240 to fill simultaneously, while the third ice-making cavity 242 has a delayed fill. Additionally, it should be understood that the flexible mold 134, discussed above, and the flexible molds 234 are constructed of the same or similar materials and include some of the same features, such as, but not limited to the mold slits 154, illustrated here as 254 for allowing the flexible molds 234 to open at a mold opening for ejecting the craft ice spheres 120 into the ice chute 208 and ultimately into an ice storage bin (e.g., ice storage bin 70).

Turning to FIG. 25, which illustrates an aspect of the disclosure with the craft ice spheres 120 being ejected from the flexible molds 234. The illustration shows an ice ejection flow path 220 (illustrated by arrows) of the craft ice spheres 120 when the fixture 235 and the flexible molds 234 are driven downward within the main housing 204 by the drive motor 210, where the flexible molds 234 are then contacted on a bottom portion by ejectors or ejection pins 252 to force the craft ice spheres 120 up, causing the mold slits 254 to spread apart and open to allow the craft ice spheres 120 to escape the ice-making cavities 236. The flexible mold 234 on the left side in FIG. 25 is illustrated as being open, while the flexible mold 234 on the right side in FIG. 25 is illustrated as being closed. The fixture 235 is positioned on top of and engages the flexible molds 234 within slots defined on the flexible molds 234, where the slots extend around an outer periphery of each ice-making cavity 236. Once the craft ice spheres 120 substantially clear and are ejected from the flexible molds 234, the craft ice spheres 120 contact a directional wall 256, which has a sloped surface, to direct the craft ice spheres 120 toward the ice chute 208. The directional wall 256 may be molded as part of the main housing 204, a top cover 306 (see FIG. 28), or attached to an inner wall 258 of the ice maker 200.

FIGS. 26-28 illustrate an alternative aspect of the disclosure directed to bottom filling a plurality of ice-making cavities 336 defined by and within flexible molds 334. The flexible molds 334 may be positioned within a main housing 304. Here, by non-limiting example, an ice maker 300 includes a similar structure to that of ice maker 200 but includes water inlets 314 that extend through a top cover 306 through water distribution fill tubes 360. Each water distribution fill tube 360 is connected to a water reservoir at a base 344 of each flexible mold 334. Each flexible mold 334 includes a water reservoir 345, which is interconnected to one of the water distribution fill tubes 360 directly, by a first connector fill tube 364 that extends between a first pair of the water reservoirs 345 (a first water reservoir 346 and a second water reservoir 348), or by a second connector fill tube 366 that extends between a second pair of the water reservoirs 345 (the second water reservoir 348 and a third water reservoir 350). The water reservoirs 345 are each operable to deliver water to an ice-making cavity of a plurality of ice-making cavities 336 defined by each flexible mold 334 for making ice therein. The plurality of ice-making cavities 336 of each flexible mold 334 may include a first ice-making cavity 338, a second ice-making cavity 340, and a third ice-making cavity 342. Additionally, it should be understood that the flexible mold 134, discussed above, the flexible molds 234, discussed above, and the flexible molds 334 are constructed of the same or similar materials and include some of the same features, such as, but not limited to the mold slits 154, illustrated here as 354 for allowing the flexible molds 334 to open at mold openings for ejecting the craft ice spheres 120 into an ice chute 308 and ultimately into an ice storage bin (e.g., ice storage bin 70).

In operation and by way of non-limiting example, water is introduced to the water distribution fill tube 360 from the refrigerator appliance 10 (e.g., from the ice maker water supply line 52). The water travels through the distribution fill tube 360 to the second water reservoir 348, which is fluidly connected to and is operable to fill the second ice-making cavity 340. The water then flows from the second water reservoir 348 to the first connector fill tube 364 and the second connector fill tube 366 at substantially the same time, which transfers the water to the first water reservoir 346 and the third water reservoir 350, respectively. The first water reservoir 346 is fluidly connected to and operable to fill the first ice-making cavity 338. The third water reservoir 350 is fluidly connected to and operable to fill the third ice-making cavity 342. Once the plurality of ice-making cavities 336 are filled with water the ice-making process begins, as previously discussed above. Again, the interconnected design allows the fill water to spread evenly to fill the water reservoirs 345 and ultimately the ice-making cavities 336 evenly and simultaneously. It should be understood that the reservoir positioned on the bottom may provide a syphon effect allowing any retained water to be pulled into the ice-making cavities 336 during the ice-making process to improve ice transparency and quality during the freezing step. The water distribution fill tube 360, the first connector fill tube 364, the second connector fill tube 366, and the water reservoirs 345 may correspond to a water delivery system that simultaneously directs or delivers water to the ice-making cavities 336 and evenly distributes water within the ice-making cavities 336.

Turning to FIG. 28, the ejection step is illustrated. Specifically, once the ice-making process is complete, the craft ice spheres 120 are ejected in substantially the same manner as discussed above with ice maker 200. The illustration shows an ice ejection flow path 320 (illustrated by arrows) of the craft ice spheres 120 when a fixture 335, which is driven by a motor (e.g., drive motor 210), and the flexible molds 334 are driven downward within the main housing 304, where the flexible molds 334 are then contacted on bottom portions by ejectors or ejection pins 352 to force the craft ice spheres 120 up, causing the mold slits 354 to spread apart and open to allow the craft ice spheres 120 to escape ice-making cavities 336. The flexible mold 334 on the left side in FIGS. 27 and 28 is illustrated as being open, while the flexible mold 334 on the right side in FIG. 28 is illustrated as being closed. The fixture 335 is positioned on top of and engages the flexible molds 334 within slots defined on the flexible molds 334, where the slots extend around an outer periphery of each ice-making cavity 336. The fixture 335 may be connected to an actuator, driver, or drive motor (e.g., drive motor 210) via a shaft (e.g., shaft 218).

A directional wall 356 is molded as an integral part of the top cover 306. As stated above, the directional wall 356 helps to push the craft ice spheres 120 toward the ice chute 308 along an ice ejection flow path 320 and ultimately reaching the ice storage bin 270, as previously discussed. It should be noted that the position of the flexible molds 334 is rotated 90 degrees relative to the configuration of the flexible molds 234 such that the flexible molds 334 are perpendicular to the layout of the flexible molds 234 in ice maker 200. This change in configuration illustrates the flexibility of the ice makers 200 and 300 to be modified as needed for a specific application or requirement.

As a non-limiting example illustrated in FIGS. 29A-31C, the ice storage bin 270 is illustrated as positioned beneath the ice maker 200 in a separated demonstrational manner. The ice maker 200 is configured to drop the craft ice spheres 120 directly down and into the ice storage bin 270. The ice storage bin 270 is shown having a curved base 222, which includes a plurality of curved sections 224 separated by ribs 226. An ice bin cavity diverter 282 is positioned at one end of the ice storage bin 270 and is configured to position the craft ice spheres 120, accordingly. Also, due to the shape of the curved base 222, the craft ice spheres 120 naturally accumulate at the center of the curved base 222, thereby maintaining organization even after a user removes one or more of the craft ice spheres 120. Additionally, the ribs 226 aid in guiding the craft ice spheres 120 along a linear path, promoting neat storage and an aesthetically pleasing appearance, which is a convenience when a user is looking for the freshest craft ice spheres 120 for consumption.

As discussed above, maneuvering the craft ice spheres 120 into the ice storage bin 70 may be accomplished by directly ejecting into the ice bin cavity 80, using a guide rim 94, a guide ramp 96, and a guide hopper 98, either individually or in combination to direct the craft ice spheres 120 to a repeatable position. With reference to FIGS. 31A-31C, additional aspects of the disclosure related to the guide hopper 98 are discussed. Specifically, the guide hopper 98 may be a straight-line tubular design that cups the ice spheres and directs them to a specific and repeatable position similar to the guide ramp 96. Additionally, the guide hopper 98 may include turns or a serpentine design allowing for additional storage while gently maneuvering the craft ice spheres 120 to the specific position. FIGS. 31A and 31B show the guide hopper 98 having a first straight section 380, a first curve 382, a second straight section 384, and a second curve 386 before exiting into an ice storage bin 370. Like the guide ramp 96, the guide hopper 98 includes a slope to allow the craft ice spheres 120 to roll or slide through an ice sphere flow path 388 exiting into the ice storage bin 370. The ice sphere flow path 388 is identified with arrows that show the direction the craft ice spheres 120 entering the first straight section 380 and moving through the guide hopper 98 to the ice storage bin 370.

As stated above, to optimize storage, the craft ice spheres 120 are initially deposited at or near the back of the ice storage bin 370 when the guide hopper 98 is used. Here ice storage bin 370 includes a sloped bottom 372 to direct the craft ice spheres 120 to a front wall 374 keeping the craft ice spheres 120 easily accessible in the first-in, first-out manner for removal by the user.

Referring to FIG. 32, a method 400 of making craft ice is illustrated. The method 400 may be stored as an algorithm or control logic within the controller 105. The method 400 starts at block 402 where a flexible-shaped flower mold (e.g., flexible mold 134, flexible mold 234, or flexible mold 334) for an ice maker is provided. Block 402 may be excluded in some configurations, particularly if the method 400 is focused on the steps of making ice. Next, at block 404 the flexible flower mold is filled with the desired or required volume of water. Water is introduced through a single filling tube that directs water into one spherical ice-making cavity (e.g., one of the ice-making cavities 136, one of the ice-making cavities 236, or one of the ice-making cavities 336) of the flexible flower mold. Due to the interconnected design of the mold, water spreads evenly to the other spherical ice-making cavities, ensuring uniform filling and even water distribution between all of the spherical ice-making cavities. Controlled filling to a specific volume is maintained based on knowing the cavities capacity and using time and frequency controls to prevent overflow. Once filled, the flexible flower mold is ready for the next step of making clear ice.

Next at block 406, the water in the flexible flower mold is frozen to produce clear ice. Producing clear ice requires a unidirectional freezing process to push air bubbles toward the bottom of the ice. This process must occur slowly, as the diffusion of air in water is inherently slow and requires unidirectional freezing, which is accomplished with the use of wire heaters (e.g., top heater 172, middle heater 174, and bottom heater 176) placed around the mold, which are controlled to regulate the freezing direction. The heater configuration may include a bottom heater, a middle heater, and a top heater housed in plastic casings that are in direct contact with the flexible flower mold. Operational sequence of the clear ice process includes starting a freezing air flow over the flexible flower mold with all heaters activated. Sequentially, the top heater is turned off first, followed by turning off the middle heater, and then finally turning off the bottom heater. This sequence promotes top-to-bottom freezing, achieving ice clarity levels exceeding 75%. The next step within the ice-making process is monitoring the temperature using sensors to monitor the temperature of the mold to ensure complete freezing of all spheres. Testing at -18°C for 24 hours using heaters attached to the bottom of the mold, following specified duty cycles. For comparison, ice was also produced without heater operation to evaluate differences in clarity. The results confirmed superior ice clarity with the heater-assisted process.

Next at block 408, the ice is harvested from the flexible flower molds. Once the water inside the mold is completely frozen, the ice must be harvested. Given that ice adheres firmly to the flexible mold, the process begins with briefly activating the heaters to melt a thin layer of ice at the mold interface, facilitating smoother ice release. Next, the ice product (e.g., craft ice spheres 120) is extracted by activating the harvesting motor to rotate the flower mold, which is attached to the bottom casing. This rotation causes the mold to press against solid ejection pins (e.g., ejection pins 152, ejection pins 252, or ejection pins 352), effectively pushing the ice out of the mold.

Finally, at block 410 the harvested ice is stored. After harvesting, the ice is directed to an ice storage bin (e.g., ice storage bin 70, ice storage bin 270, or ice storage bin 370) located beneath the ice maker (e.g., ice maker 100, ice maker 200, or ice maker 300). A hopper guides the ice (e.g., craft ice spheres 120) into the back of the bin, allowing for first-in, first-out consumption. This method ensures that older ice is used before newly produced spheres. Thus, the final step is to remove the ice for consumption and activate the process all over creating new ice.

In one aspect it should be understood that the ice-making appliance is designed to produce clearer spherical ice ranging from 2 inches to 2.5 inches in size, with ice clarity levels between 80% to 99%. The setup features a fixed outer structure/housing attached to the freezer liner. Inside this housing, a moving top half plastic mold works in conjunction with a spherical silicone mold, which is affixed to the bottom of the fixed plastic housing.

Movement of the top half of the mold is translated with the assistance of a motor assembly. A top guiding feature is integrated within the fixed plastic housing for additional support. The mold freezes from top to bottom with only the bottom heater (e.g., bottom heater 176) operational during the ice-making cycle. The heater may operate at a 75% duty cycle (45 seconds ON/15 seconds OFF) for 16 hours, followed by a 20% duty cycle (12 seconds ON/48 seconds OFF) for 5 hours to allow slow freezing. The mold then cools for 2.5 hours before the ice harvesting process.

During ice removal, both the top and bottom heaters may be activated simultaneously to detach the ice from the mold. This method ensures ice clarity up to 95% with minimal haziness, producing six clear spherical ice balls per day. In fast ice mode, with heaters turned off, the system yields twelve to eighteen hazy spheres per day.

The Flower Mold Sphere Ice Maker revolutionizes the production of craft ice through its innovative, single-cavity, flexible mold design. With automated processes for water filling, ice-making, harvesting, and storage, this system offers an efficient, user-friendly solution for high-quality spherical ice production. The addition of alternative storage solutions, such as the curved bin and hopper designs, further enhances the functionality, organization, and aesthetic appeal of the ice storage process. The integration of advanced ice-making appliances capable of producing larger, clearer spherical ice sets a new industry standard, ensuring superior ice clarity, operational simplicity, and user satisfaction.

As used herein, the terms “substantial,” “substantially,” and variations thereof are intended to note that a described feature is equal or approximately equal to a value or description. For example, a “substantially linear” feature is intended to denote a feature that is linear or approximately linear. Moreover, “substantially” is intended to denote that two values are equal or approximately equal. For example, “substantially” may denote values within 10% of each other, within 5% of each other, within 2% of each other, within 1% of each other, within 0.5% of each other, within 0.25% of each other, within 0.1% of each other, within 0.01% of each other, etc.

It should be understood that the designations of first, second, third, fourth, etc. for any component, state, or condition described herein may be rearranged in the claims so that they are in chronological order with respect to the claims. Furthermore, it should be understood that any component, state, or condition described herein that does not have a numerical designation may be given a designation of first, second, third, fourth, etc. in the claims if one or more of the specific component, state, or condition are claimed.

The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments may be combined to form further embodiments that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics may be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. As such, embodiments described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.

While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.

Claims

1. An ice maker for a refrigerator appliance comprising: a flexible mold defining ice-making cavities that are interconnected to distribute water uniformly within the ice-making cavities; a drive configured to move the flexible mold between an ice-making position and an ice-harvesting position; ejectors positioned adjacent to the flexible mold and configured to engage the flexible mold to eject ice from the ice-making cavities; and a storage bin configured to receive the ice when ejected from the ice-making cavities.

2. The ice maker of claim 1, wherein the flexible mold is configured to deform in response to engagement with the ejectors and return to a non-deformed shape in response to disengagement with the ejectors.

3. The ice maker of claim 1, wherein the flexible mold defines water distribution channels that interconnect the ice-making cavities.

4. The ice maker of claim 1 further comprising a top casing and a bottom casing that are configured to enclose the flexible mold when in the ice-making position to provide rigid support to the flexible mold.

5. The ice maker of claim 1, further comprising heaters positioned around the flexible mold, wherein the heaters facilitate unidirectional freezing for producing clear ice.

6. The ice maker of claim 1, wherein the storage bin comprises a sloped base and a diverter for organizing the ice.

7. The ice maker of claim 1, wherein the ice-making cavities are spherical.

8. An ice maker for a refrigerator appliance comprising:

a flexible mold defining a plurality of ice-making cavities;

a water inlet configured to direct water simultaneously into each of the ice-making cavities;

a drive configured to move the flexible mold between an ice-making position and an ice-ejection position;

ejectors configured to push ice from the flexible mold upon completion of a freezing process and in response to the flexible mold transitioning to the ice-ejection position; and

a storage bin configured to receive and organize the ice when ejected from the ice-making cavities.

9. The ice maker of claim 8, wherein the flexible mold defines a slit configured to open and release the ice in response to engagement with the ejectors.

10. The ice maker of claim 8, wherein the water inlet is positioned at a top of the flexible mold to facilitate uniform water distribution.

11. The ice maker of claim 8, further comprising a refrigeration system configured to direct cooled air around the flexible mold.

12. The ice maker of claim 8, wherein the ejectors comprise pins configured to engage a mold contour positioned on the flexible mold at a base of each ice-making cavity.

13. The ice maker of claim 8, wherein the storage bin includes a guide ramp and at least one diverter.

14. The ice maker of claim 8, wherein the ice-making cavities are spherical.

15. The ice maker of claim 8, wherein the water inlet is integrated into the flexible mold.

16. An ice maker comprising:

a flexible mold defining ice-making cavities, operable to deform and open to eject ice from the ice-making cavities, and operable to return to a non-deformed position in response to ejecting the ice from the ice-making cavities; and

a water delivery system that is configured to direct water simultaneously into each of the ice-making cavities and evenly distribute the water within the ice-making cavities.

17. The ice maker of claim 16 further comprising a drive configured to move the flexible mold between an ice-making position and an ice-ejection position.

18. The ice maker of claim 17 further comprising ejectors configured to push ice from the flexible mold upon completion of a freezing process and in response to the flexible mold transitioning to the ice-ejection position.

19. The ice maker of claim 16 further comprising a storage bin configured to receive the ice when ejected from the ice-making cavities.

20. The ice maker of claim 16, wherein the ice-making cavities are spherical.