Ice machine with enhanced directional freezing capability

Abstract

Various embodiments of the present disclosure relate to an ice machine capable of producing directionally-frozen ice segments. In one example embodiment an ice machine includes a basin having four sidewalls and a bottom. The bottom of the basin includes an aperture, which is exposed or enclosed by a gate valve located on the aperture. The ice machine includes a grid mold inset to the basin. The grid mold includes exterior and interior sidewalls to form cavities which house a liquid that is directionally frozen by the condenser and overhead fans of the ice machine. The ice machine includes heat wires embedded into the exterior and interior sidewalls of the grid mold. The ice machine includes a funnel beneath the grid mold to guide the ice segments from the grid mold, through the aperture, and into a storage container.

What is claimed is: 
     
         1 . An ice machine comprising:
 a basin having four sidewalls and a bottom, wherein the bottom of the basin includes an aperture;   a grid mold inset to the basin comprising exterior sidewalls and interior sidewalls, wherein the exterior sidewalls and the interior sidewalls are insulated, and wherein cavities formed by the grid mold house ice segments, such that the ice segments are directionally-frozen;   a funnel located beneath the grid mold, wherein the funnel guides the ice segments to the aperture of the basin;   a gate valve, wherein the gate valve is located on the aperture of the basin; and   embedded heat wires located within the exterior sidewalls and the interior sidewalls of the grid mold, wherein the embedded heat wires activate the movement of the ice segments from the grid mold, down the funnel, through the aperture of the basin, and into a storage container.   
     
     
         2 . The ice machine of  claim 1  wherein the exterior sidewalls and the interior sidewalls of the grid mold are slanted, such that the thickness of the exterior sidewalls and the interior sidewalls gradually tapers. 
     
     
         3 . The ice machine of  claim 1  wherein the gate valve is driven by a motor, such that when the motor shuts the gate valve, the bottom of the basin is fully enclosed. 
     
     
         4 . The ice machine of  claim 1  wherein the exterior sidewalls and the interior sidewalls of the grid mold form rectangular cavities. 
     
     
         5 . The ice machine of  claim 4  wherein the ice segments formed within the grid mold are frozen to a depth of approximately two inches. 
     
     
         6 . The ice machine of  claim 1  wherein the exterior sidewalls and the interior sidewalls of the grid mold form approximately spherical cavities. 
     
     
         7 . The ice machine of  claim 1  wherein the storage container comprises storage to hold six cycles of ice before reaching capacity. 
     
     
         8 . The ice machine of  claim 1  wherein the storage container tempers the ice segments to maintain its clear and frozen state. 
     
     
         9 . The ice machine of  claim 1  wherein a liquid line is connected to the basin. 
     
     
         10 . The ice machine of  claim 1  wherein the ice segments are directionally-frozen from top to bottom. 
     
     
         11 . A method of operating an ice machine comprising:
 closing a gate valve, by a gate valve motor, located on an aperture at the bottom of a basin, such that the aperture at the bottom of the basin is fully enclosed;   filling the basin with liquid, by a pump connected to a liquid line, from the bottom of the basin to the top of a grid mold inset to the basin, the grid mold comprising:
 exterior sidewalls and interior sidewalls, wherein the exterior sidewalls and the interior sidewalls are insulated, and wherein cavities formed by the grid mold house liquid; 
   initiating freezing wherein a condenser and fans transform the liquid into ice segments, such that the ice segments are directionally-frozen;   completing freezing, wherein the condenser and fans are shut off;   draining, by the pump connected to the liquid line, excess liquid from the basin;   opening the gate valve, by the gate valve motor, such that the aperture at the bottom of the basin is fully exposed;   activating embedded heat wires located within the exterior sidewalls and the interior sidewalls of the grid mold, wherein the ice segments fall from the grid mold, guided by a funnel, through the aperture at the bottom of the basin and into a storage container; and   maintaining, by the storage container, the ice segments in their frozen state.   
     
     
         12 . The method of  claim 11  wherein the timing for completion of freezing is dictated by the depth of ice frozen in the grid mold. 
     
     
         13 . The method of  claim 11  wherein the exterior sidewalls and the interior sidewalls of the grid mold are slanted, such that the thickness of the exterior sidewalls and the interior sidewalls gradually tapers. 
     
     
         14 . The method of  claim 11  wherein the exterior sidewalls and the interior sidewalls of the grid mold form rectangular cavities. 
     
     
         15 . The method of  claim 11  wherein the completion of freezing is based on achieving a desired temperature and a desired time duration, further indicating that the ice segments formed within the cavities of the grid mold are frozen to a depth of approximately two inches. 
     
     
         16 . The method of  claim 11  wherein the exterior sidewalls and the interior sidewalls of the grid mold form approximately spherical cavities. 
     
     
         17 . The method of  claim 11  wherein the storage container comprises storage to hold six cycles of ice before reaching capacity. 
     
     
         18 . The method of  claim 11  wherein the liquid line is connected to the basin. 
     
     
         19 . The method of  claim 11  wherein the freezing process produces ice segments which are directionally-frozen from top to bottom. 
     
     
         20 . A microcontroller of an ice machine comprising:
 one or more processors; and   one or more memories having stored thereon instructions that, upon execution by the one or more processors, cause the microcontroller to at least:
 cause a gate valve motor to close a gate valve located on an aperture at the bottom of a basin, such that the aperture at the bottom of the basin is fully enclosed; 
 cause a pump to move liquid from a reservoir into a liquid line to fill the basin with liquid from the bottom of the basin to the top of a grid mold inset to the basin, the grid mold comprising:
 exterior sidewalls and interior sidewalls, wherein the exterior sidewalls and the interior sidewalls are insulated, and wherein cavities formed by the grid mold house the liquid; 
 
 retrieve data from a liquid sensor, wherein the liquid sensor monitors the liquid level of the basin; 
 based on a determination that the liquid has successfully filled the basin from the bottom of the basin to the top of the grid mold, cause the pump to pause the movement of liquid from the reservoir, and cause a condenser and one or more fans to power on, such that the condenser and the one or more fans transform the liquid into ice segments, and wherein the ice segments are directionally-frozen; 
 retrieve data from a temperature sensor or sensors, wherein the temperature sensor or sensors monitor the temperature of air or liquid at a given location in the ice machine; 
 based on a determination that temperature of the basin is at least a predetermined value representative of the liquid in the cavities of the grid mold having transformed into ice segments, cause the condenser and the one or more fans to power off; 
 cause a pump to move excess liquid from the basin into the liquid line, such that the excess liquid drains out of the basin via the liquid line; 
 cause a gate valve motor to open the gate valve, such that the aperture at the bottom of the basin is fully exposed; 
 cause heat wires to activate, wherein the heat wires are embedded into the exterior sidewalls and the interior sidewalls of the grid mold, further causing the ice segments to fall from the grid mold through the aperture at the bottom of the basin and into a storage container; and 
 cause temperature controls within the storage container to maintain the ice segments in their frozen state.