Methods and systems for improving and maintaining the cleanliness of ice machines

Abstract

The use of the following techniques to clean air: (1) inlet air filtration, (2) continuous recirculation air filtration, (3) water filtration and disinfection, (4) use of an air curtain in the ice bin opening, and (5) provision of clean air to the air assist pump during the harvest cycle.

Claims

1. An ice maker comprising: (1) an ice making compartment having therein: an evaporator; a sump which holds water; a distributor; a pump that directs said water from said sump to said distributor and then to said evaporator whereupon ice pieces form; and a chute through which said ice pieces are discharged from said ice making compartment; an air moving device communicating with an anti-microbial filter disposed in or about said ice making compartment to substantially remove microbials from air prior to said air entering said ice making compartment, wherein said air moving device creates a net positive air flow of purified air from said anti-microbial filter into said ice making compartment, wherein said anti-microbial filter is at least one selected from the group consisting of: a water spray, an anti-microbial pesticide mechanism, a water reservoir, and ozone, and (2) an ice bin disposed below said ice making compartment for receiving ice via said chute.

2. The ice maker of claim 1, wherein said anti-microbial filter is said water spray.

3. The ice maker of claim 2, wherein said air moving device directs said air through a vessel where filter water has been filtered by a microbial control water filter and is sprayed or cascaded across a flow path of said air to form said water spray.

4. The ice maker of claim 3, wherein said air flows from said vessel to said ice making compartment creating said net positive air flow of purified air.

5. The ice maker of claim 1, wherein said anti-microbial filter is said anti-microbial pesticide mechanism.

6. The ice maker of claim 5, wherein said anti-microbial pesticide mechanism filters using a mechanism selected from the group consisting of ultraviolet air stream, ozone, free radical generation, and any combination thereof.

7. The ice maker of claim 1, wherein said anti-microbial filter is said water reservoir.

8. The ice maker of claim 1, wherein said air is communicated to said anti-microbial filter prior to being communicated to said ice making compartment.

9. The ice maker of claim 1, wherein said air in said ice making compartment is communicated to said anti-microbial filter to be circulated through said filter and discharged from said filter to be returned into said ice making compartment.

10. An ice maker comprising: an ice bin; and an ice making compartment which comprises: an evaporator; a sump which holds water; a distributor; a pump that directs said water from said sump to said distributor and then to said evaporator; a pressurized cylinder metering an inert atmosphere of purified air into said ice making compartment that fills said ice making compartment with the purified air and creates a net positive flow of purified air into said ice making compartment so that outside contaminants do not enter said ice making compartment; and a sealing device that seals a volume of the ice making compartment with the purified air and blocks ambient air from entering said ice making compartment, wherein said purified air is free of micro-organisms.

11. The ice maker of claim 10, further comprising: a mechanical pressure regulator operably connected to said pressurized cylinder, wherein said mechanical pressure regulator meters said purified air and creates said positive air pressure.

12. The ice maker of claim 10, further comprising a measurement device that measures an air pressure in said ice making compartment and a controller to energize or de-energize an air moving device to maintain an amount of pressure in said ice making compartment.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIGS. 1A and 1B provide an illustration of a conventional automatic ice making machine with the add-on cleaning/sterilizing system located in two different locations.

(2) FIG. 2 provides a line diagram describing an embodiment for the coolant/refrigerant system of the conventional ice machine of FIG. 1.

(3) FIGS. 3A and 3B provide line diagrams and drawings for an embodiment of the water/ice system of the conventional ice machine of FIG. 1.

(4) FIGS. 4A and 4B provide respectively an inside view and front view drawing of an embodiment of the cleaning/sterilizing system of the conventional ice machine of FIG. 1A.

(5) FIG. 5 provides further details for an embodiment for the control panel for the cleaning/sterilizing system of FIG. 4.

(6) FIG. 6 is a perspective view of an ice making machine which can be adapted to receive any of the filtration and cleaning embodiments according to the present disclosure.

(7) FIG. 7 is a block diagram of air cleaning system according to one embodiment of the present disclosure, wherein air that enters the ice making machine is filtered through the water reservoir, water spray or anti-microbial pesticide mechanism prior to entering the ice making machine.

(8) FIG. 8 is a block diagram of air cleaning system according to one embodiment of the present disclosure, wherein air in an ice machine food zone is directed into a filter or disinfection module and directed from the filter or disinfection module into the ice machine food zone.

(9) FIG. 9 is a block diagram of air cleaning system according to one embodiment of the present disclosure, wherein gas is metered into an ice machine food zone.

(10) FIG. 10 provides a line diagram and drawing of a water cleaning system according to one embodiment of the present disclosure, wherein micro-biological control is connected to an inlet of a water supply.

(11) FIG. 11 provides an illustration of an automatic ice making machine having an air cleaning system according to one embodiment of the present disclosure, wherein air is flowed across an opening of the storage bin to form an air curtain.

(12) FIG. 12 provides a line diagram and drawing of air cleaning system according to one embodiment of the present disclosure, wherein an air pump pumps air into an interface of ice and an evaporator to provide pressure into the interface.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(13) An ice making machine 120 according to FIG. 6, includes a pair of evaporator assemblies 124, a water pump 128, a water sump 132, and an ice chute 136 through which ice pieces are discharged to a bin (not shown) for collection and storage. Although the ice making machine 120 illustrated in FIG. 6 is adapted for forming a geometric grid of cubes connected by a thin bridge layer of ice, it should be noted that the various aspects can be applied to ice machines adapted to produce ice in any other shape formed in unconnected or connected assemblies on any type of ice forming surface (e.g., individual pockets or other receptacles, one or more troughs, a flat or substantially flat ice forming sheet, and the like). With reference again to the embodiment of FIG. 6, each evaporator assembly 124 of the illustrated ice making machine 20 includes an ice-forming surface 140.

(14) Each evaporator assembly 124 has a shield 144 adjacent the ice-forming surface 140. Although not required, the shield 144 can be used to control the discharge of ice from the ice-forming surface 140 during a harvesting cycle of the ice making machine 120. The ice-forming surface 140 and the shield 144 are oriented substantially vertically and are spaced a relatively small distance apart, although it will be appreciated that the ice-forming surface 140 and/or the shield 144 can be oriented in other manners while still performing their respective functions.

(15) A flexible curtain can be attached to the shield 144 and can extend from a bottom portion of the shield. For example, each evaporator assembly 124 in the illustrated embodiment has a flexible curtain attached to the shield 144. The flexible curtain is angled or curved toward the ice-forming surface 140 in an at-rest state, but is pliable and easily deflected outwardly away from the ice-forming surface 140 when contacted by ice pieces. In other embodiments, the flexible curtain can have other shapes also capable of being deflected when contacted by ice falling from the ice-forming surface 140.

(16) An evaporator 148 is connected to each ice-forming surface 140 of the illustrated ice making machine 120 in order to chill the ice-forming surfaces 140. The evaporators 148 are part of a refrigeration system, which circulates a refrigerant through a refrigeration cycle to chill each ice-forming surface 140.

(17) As shown in FIG. 6, the ice chute 136 is positioned between the evaporator assemblies 124 to receive ice pieces therefrom. One evaporator assembly 124 is positioned adjacent the water pump 128 (near a first end 151 of the ice making machine 120), and the other evaporator assembly 124 is substantially remote from the water pump 128 (near a second end 152 of the ice making machine 120). The water sump 132 includes portions adjacent the first and second ends 151 and 152 of the ice making machine 120 to receive water from the adjacent evaporator assemblies 124 as described in further detail below. The water sump 132 extends around both sides of the ice chute 136 such that the portion of the water sump 132 adjacent the second end 152 of the ice making machine 120 is in communication with the portion of the water sump 132 adjacent the first end 151. The water pump 128 is in fluid communication with the water sump 132 at the first end 151 of the ice making machine 120. In other embodiments, water can be received within a water sump 132 having any other shape and size desired, such as a pan located generally beneath one or more evaporator assemblies 124, one or more troughs positioned to receive water from one or more evaporator assemblies 124, and the like.

(18) Unless otherwise noted, the description of the evaporator assembly 124 (and its components) herein applies to both evaporator assemblies 124, which are substantially identical in structure and operation in the illustrated embodiment. Any number of evaporator assemblies 124 can be provided as part of the ice making machine 120, such as one, three, or more evaporator assemblies 124.

(19) As shown in FIG. 6, an ice barrier 153 is positioned at the bottom of the evaporator assembly 124 along a boundary wall 154 separating the water sump 132 and the ice chute 136. The ice barrier 153 of the illustrated embodiment is positioned vertically above the water sump 132 and the ice chute 136, but substantially below the ice-forming surface 140. The ice barrier 153 is rotatably mounted, and is movable about a pivot axis between a first orientation and a second orientation. In some embodiments, the ice barrier 153 is rotatably mounted to the evaporator assembly 124, while in others the ice barrier 153 is also or instead rotatably mounted to other structure of the ice making machine 120.

(20) Switch 180 senses the presence/absence of a magnet, not shown, and controls the operation (e.g., on or off mode) of the ice making machine 120 based at least in part upon the orientation of the ice barrier 153. Generally, the ice making machine 120 is on when the ice barrier 153 is in the first orientation, and is turned off by the switch 180 when the ice barrier 153 is in the second orientation. In some embodiments, the switch 180 includes a Hall-effect sensor to detect the presence or absence of the magnet. The switch 180 in the illustrated embodiment is configured to interrupt the ice-making ability of the ice making machine 120 by stopping the water flow over the ice-forming surface 140 (driven by the water pump 128) and/or by stopping the refrigeration cycle that chills the ice-forming surface 140. For this purpose, the switch 180 may be coupled to a controller (not shown) in communication with the water pump 128 and/or the refrigeration cycle.

(21) The features of FIGS. 7-12 that are similar to FIGS. 1-6 will use the same reference numerals.

(22) One embodiment according to the present disclosure is shown in FIG. 7, which pertains to an inlet air filtration. That is, one method of protecting the ice machine is through filtration of air that is convected or communicated into a food zone portion 205 of the ice making machine. Food zone portion 205 includes sump 136, evaporator assembly 124 and a distributor that distributes water to evaporator assembly 124, for example, distributor 7. This can be accomplished through one or more of the following including a water reservoir or water spray or anti-microbial pesticide mechanism 200:

(23) Water spray 200 removes contaminants/particles entering into food zone portion 205 of the ice machine. This is a common practice in other industries to reduce or eliminate contaminants in the air flow. Paint spray booths utilize water spray filtration to contain paint overspray. Water is cascaded across the flow path of the exhaust air and the paint particulates are retained in the water. In an ice machine application air entering into the food zone portion 205 of the ice making machine, as shown by arrows 203 and 210, by means of an air moving device, for example, a fan, would pass through a vessel 201 where recirculating water that has been filtered by a microbial control water filter is sprayed or cascaded across the flow path collecting contaminants. Air would then enter into the food zone portion 205 of the ice machine, as shown by arrow 230, and attached bin, creating a net positive flow of purified air into the machine, excluding the opportunity for micro-organisms to enter and contaminate the food zone.

(24) It is also possible to purify the air entering into the ice machine through the use of an anti-microbial pesticide mechanism 200, such as direct ultraviolet (UV) exposure to the air stream, or ozone or other free radical generation and mixing with the airstream. In an ice machine air entering into the food zone portion 205 of the ice making machine, as shown by arrows 203 and 210, by means of an air moving device, for example, a fan, would pass through a vessel 201 where direct ultraviolet (UV) exposure to the air stream, or ozone or other free radical generation and mixing with the airstream. Air would then enter into the food zone portion 205 of the ice machine, as shown by arrow 230, and attached bin, creating a net positive flow of purified air into the machine, excluding the opportunity for micro-organisms to enter and contaminate the food zone.

(25) An alternate method to inlet air filtration shown in FIG. 8 is to employ a filter system or pesticide system 310 of any of the types described in the inlet air filtration method to continuously clean recirculated air contained in the food zone to filter micro-organisms out of the air volume contained within the food zone portion 205 of the ice machine and bin:

(26) Intake of air at one end of the combined food zone via a duct system, as shown by arrow 320.

(27) Circulation of the air through any one of several high efficiency filters, including HEPA or water spray, or through a disinfection module using UV, ozone, or other free radical, as shown by arrow 330.

(28) Discharge of the air into the opposite end of the combined food zone, as shown by arrow 340, ensuring complete turnover of the enclosed air to eliminate all contaminants introduced into the food zone by leakage or door/machine compartment openings.

(29) Still another method of cleaning the ice machine according to the present disclosure is by sealing the ice machine by a sealing device that blocks entry of outside air or ambient air into the ice machine and producing a positive internal pressure, so that outside contaminants (micro-organisms) are prevented from entering into the machine, as shown in FIG. 9. This can be accomplished by: A system where a pure (free of micro-organisms) and inert gas is metered into the ice machine providing positive air pressure in food zone portion 205 and preventing any infiltration of outside air into the food zone. In this embodiment the inert gas is contained in a pressurized cylinder 410 and is metered into food zone portion 205 using a mechanical pressure regulator 415, as shown by arrows 420, 425. The advantage of this method is that it is non-electrical and will continue to operate during a power loss. With other devices that are dependent on electricity any claims of sanitation protection would only apply while the unit is powered. In the event of a power loss there would be a loss of sanitation protection to the unit. Use of nitrogen as the inert gas has the added advantage of inhibiting the growth of most common micro-organisms, providing additional protection. An enhancement to this method would be the addition of devices 429 to measure the air pressure inside food zone portion 205 and a control 430 to energize or de-energize the air moving device, for example, a fan, to maintain a specific amount of pressure. This would be a more energy efficient method than continuous operation.

(30) Another path for the introduction of micro-organism is through the water entering the ice machine. Municipal water supplies provide safe water for consumption, but are not completely free of micro-organisms. By integrating a micro-biological control 550 into the inlet water supply 1, as shown in FIG. 10, which can consist of membrane filtration, or treatment with UV light, silver ions, anti-microbials, or ozone, the foodzone for the ice machine can be maintained as a sterile environment.

(31) These methods combined with an automatic cleaning system for the ice machine that removes scale build-up would eliminate the necessity of opening the machine for sanitizing and cleaning due to water-borne contaminants.

(32) Another path for microbials to enter into the ice machine is through the storage bin door 31, shown in FIGS. 1A and B. Referring to FIG. 11 where storage bin door 31 has been removed for clarity, to remove ice from the storage bin 30 a hinged bin door 31 is opened and the ice is manually scooped from the bin. When bin door 31 is opened air is brought into the storage bin which is in contact with the ice machine 33. Air from bin 30 circulates up into ice machine 33.

(33) Incorporating an air curtain, as shown by arrows 660, into ice storage bin 30 the ingress of outside air into the storage bin 30 can be controlled. When bin door 31 is opened air inside storage bin 30 is flowed, for example, by a fan, at a high velocity across the opening of storage bin 30. This air flow acts as a curtain to prevent air from entering. When bin door 31 is closed the power to the air flow device, not shown, is de-energized. This method coupled with the continuously circulated/purified air described above will provide the desired protection to ice machine 33.

(34) Optionally, combining the air curtain with the use of an anti-microbial bin or bin liner 670 further enhances or ensures cleanliness by preventing or significantly inhibiting contaminant growth in the food zone.

(35) Furthermore, combining the air curtain and anti-microbial bin or bin liner with the use of scoops also made of anti-microbial material further preserves the cleanliness of the bin area.

(36) Referring to FIG. 12, another area for contamination which requires cleaning according to the present disclosure is during harvest cycle, when the ice making device in order to release ice from the evaporator surface of evaporator plate 6 uses a number of methods to assist in the harvesting of ice. Typically hot gas in the refrigeration system is passed through the evaporator plate 6 to melt the interface between the ice and the evaporator surface. To speed the harvest of the ice often mechanical means are employed. These can consist of electrical solenoids that actuate a metal pin into the interface providing slight pressure to the ice and causing it to release quicker. Another method is through the use of an air pump 770 to pump air into the interface, as shown by arrows 780, which provides pressure into the interface of the ice and evaporator plate 6. Typically the air pump 770 gets its air external of the ice making evaporator compartment (food zone). To provide clean air to the air pump 770, an air inlet 790 to the air pump 770 would be in the food zone of the ice machine where the air is treated through one of the means described herein. For example, the air is treated by a water reservoir or water spray or anti-microbial pesticide mechanism, membrane filtration, or treatment with UV light, silver ions, anti-microbials, or ozone. If an inert gas is used to positively pressurize the food zone, this inert gas, for example, from pressurized cylinder 410, can be used to replace the pressurized air supplied by the air assist pump.

(37) While we have shown and described several embodiments in accordance with our invention, it is to be clearly understood that the same may be susceptible to numerous changes apparent to one skilled in the art. Therefore, we do not wish to be limited to the details shown and described but intend to show all changes and modifications that come within the scope of the appended claims.