Note: Descriptions are shown in the official language in which they were submitted.
BACKGROUND
STATE OF THE ART
[0001] The present disclosure relates to ice structures, and in particular to
methods of
forming ice structures to be covered in ice to make temporary structures, art
or
public attractions.
FIELD OF ART
[0002] There are a variety of situations in which structures are made of snow
or ice.
For example, many cities have winter festivals which include contests for
displays
made from ice. In some locations, buildings are made of ice during the
wintertime.
Some northern countries even have hotels which are formed by ice or snow which
has been carved or otherwise shaped to provide sleeping rooms, restaurants,
etc.
[0003] One popular use for ice structures is as an entertainment
destination. In
many locations a structure is built and then sprayed with water so that the
underlying
structure is encased in ice. Usually, the sprayed water is allowed to drip so
as to
form icicles hanging from the underlying structure. The structures, commonly
referred to as ice castles or ice palaces, can be provided with colored
backlighting
so as to form pieces of art for viewing by the public. In some cases, the ice
sculptures are so large that they can include tunnels and walkways where
visitors
can actually walk on/through the ice castle. As water continues to be sprayed,
the
structure grows, often to the height of 2 or more stories.
[0004] While some have used wood or steel structures as the initial starting
points for
applying the water, when lights are used the generally opaque wood or steel is
visible through the ice and makes the ice castle appear less natural. One
solution to
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this problem is disclosed in U.S. Patent No. 8,511,042 ("the '042 patent").
The '042
patent shows a method of constructing structures in which a table or other
raised
structure is used with running water or sprinklers to create a number of
icicles
extending downwardly from the table. Once the icicles have reached a desired
size
they are broken off and attached to one another by the use of slush or an
ice/water
mixture. These icicles are used as a framework which is over sprayed with
water to
form the ice structure.
[0005] One concern with the methodology used in the '042 patent is that
icicles are
somewhat unpredictable in their formation and may be substantially broader on
one
end than the other. Icicles also may have inconsistent thickness and density
along
their length. Another concern is that a substantial amount of water may be
used
simply forming the icicles used to form the initial structure.
[0006] Still another concern with the method taught in the '042 patent is
that slush is
used to hold each icicle to the other parts of the frame. This requires those
building
the structure to attach hundreds of icicles to using wet snow. This can soak
through
the worker's gloves and get on their clothing. When working outside during sub-
freezing temperatures, this can get uncomfortable and, in some cases, may even
risk frostbite.
[0007] Other improvements have been made in the building of ice structures.
For
example, in U.S. Patent No. 10,663,204, it is taught to make ice logs out of
water
filed sleeving. The amount of water in the sleeving can be used to control the
overall
shape of the ice logs, as can the manner in which the sleeving is disposed on
the
ground or other support structure. Additionally, the ice logs can be cut and
stacked
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with the sleeving, thereby helping to prevent logs from being frozen together.
The
ice logs allow building of structures much more like building with logs or
conventional
lumber.
[0008] The system disclosed in the '204 patent is advantageous in that the
horizontal and vertical structures can be placed on one another without the
use of
slush. Because the ice logs are generally round, however, the simply laying
them on
top of another ice log does not provide as much potential stability while the
ice logs
are being covered with water and frozen together.
[0009] In addition to these challenges, the method with which water is
sprayed on
the underlying icicles or ice logs can create issues. The water is typically
conveyed
to a raised sprinkler by plastic sprinkler tubing, typically PVC. Because the
water is
warmer than freezing, the sprinkler tubing is warmer than freezing and can
slowly
cut through the ice. Additionally, any water not sprayed by the sprinkler and
running
down the tubing will melt ice. Thus, when looking at the sprinkler from above,
it is
often possible to see all the way to the ground around the sprinkler. This
allows the
sprinkler tubing to bend and makes control of the water pattern less
predictable.
[0010] Thus, there is a need for a method for constructing ice structures
which is
relatively easy to use and provides improved predictability.
SUMMARY OF THE INVENTION
[0011] A method for creating ice structures may include the formation of a
plurality of
ice logs. The ice logs may then be joined together to build a desired ice
structure.
[0012] In accordance with one aspect of the invention, the ice logs are
formed by
filling elongate sleeves with water and allowing the water to freeze. The
elongate
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sleeves are then removed from the ice log formed by the frozen water and the
ice
logs are used to construct the desired ice structure, or a frame upon which a
desired
ice structure is formed.
[0013] In accordance with another aspect of the invention, the elongate
sleeves may
be formed from a thin, disposable plastic, polyurethane or other material. The
material can then be filled with water and may be bent or otherwise disposed
in a
desired shape to form an ice log having the desired characteristics.
[0014] In accordance with another aspect of the invention, once water in
the
elongate sleeves has frozen, a saw may be used to cut ice logs of the desired
size.
Thus, for example, an initial ice log may be formed which is 6 inches in
diameter and
60 feet long. A chainsaw can then be used to cut the ice log into five 8-foot
segments and two 10-foot segments.
[0015] In accordance with another aspect of the invention, the ice logs can
be
connected to form a structure which has 2 or more stories and preplanned
pathways, balconies, etc., along which visitors can walk.
[0016] In accordance with another aspect of the invention, the ice logs can be
shaped
at some position to allow the ice logs to rest on top of one another with more
stability.
[0017] In accordance with another aspect of the invention, the ice logs can be
inserted into a hole formed in another ice log so as to hold the first ice log
in place so
that the ice logs may freeze together without the need for using slush.
[0018] In accordance with another aspect of the invention, ice beams may be
formed
in a mold having at least one generally flat side so as to facilitate
placement of the
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ice beam on the end of an ice log or another ice beam. In some embodiments, a
mold having a generally rectangular or square internal cross-section may be
used so
that the ice beams have generally flat sides which facilitate stacking the ice
beams
on top of one another without the use of slush.
[0019] In accordance with another aspect of the present disclosure, the ice
beams
may be formed within a sleeve disposed within the mold so that the ice beam
can be
removed from the mold without sticking and so that the ice beams can be kept
with
less likelihood of sticking together.
[0020] In accordance with another aspect of the invention, the ice logs can
have a
hole formed therein so as to allow an ice spike to be inserted to attach to
ice logs
and/or ice beams together to help hold them in place until water can be used
to
freeze them into a solid mass.
[0021] In accordance with another aspect of the invention, the mold may
have one or
more projection which can pre-form a hole into the ice beams to facilitate
joining the
ice beams with an ice spike.
[0022] In accordance with another aspect of the present disclosure, the water
tubes
used to spray water on the ice may be thermally isolated from the ice logs to
prevent
movement of the tubing and damage to the ice logs.
[0023] In accordance with another aspect of the present disclosure, an
inflatable or
otherwise collapsible mold can be used to form ice to create rooms with domed
ceilings.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Various embodiments of the present disclosure are shown and described
in
reference to the numbered drawings wherein:
[0025] FIG. 1 illustrates a pair of sleeves having water contained therein
for making
ice logs;
[0026] FIG. 2 illustrates a sleeve having water contained therein for
making an ice
log in the shape of a candy cane;
[0027] FIG. 3 illustrates an ice log formed in an oval shape as could be
used to form
an oval-shaped room;
[0028] FIG. 4 illustrates an end view of a pair of arcuate ice logs forming
a tunnel and
a pair of ice logs being used to anchor the arcuate ice logs;
[0029] FIG. 5 shows a support structure formed out of ice logs making
different
shapes upon which icicles can be formed to produce a work of art or part of an
ice
castle;
[0030] FIG. 6 shows a pair of ice logs being subjected to sprinklers or
another water
sprinkling device so as to form icicles on the ice logs;
[0031] FIG. 7 illustrates an ice structure built from ice logs having a
tunnel and a set
of stairs leading to a second story balcony;
[0032] FIG. 8 shows a top view of a house having a second story with a balcony
formed in accordance with principles of the present disclosure;
[0033] FIG. 9 shows a cross-sectional view of a sleeve partially filled
with water to
form a base;
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[0034] FIG. 10 shows a side view of a base having a plurality of ice logs
inserted
vertically to support the ice logs;
[0035] FIG. 11 shows a flowchart for forming ice logs in accordance with
principles of
the present disclosure; and
[0036] FIG. 12 shows a flowchart for building an ice structure in
accordance with
principles of the present disclosure; and
[0037] FIG. 13 show a side view of an ice log being formed with lighting or
power
cables disposed therein;
[0038] FIG. 14 shows an alternate configuration of an ice slide made in
accordance
with the present disclosure;
[0039] FIG. 15 shows an alternate ice log that could be used to make an ice
slide;
[0040] FIG. 16 shows a cross-sectional view of an ice log which is being
used as a
base;
[0041] FIG. 17 shows a cross-sectional view of an alternate embodiment of
an ice
log which is being used as a base;
[0042] FIG. 18 shows a side view of an ice structure built in accordance with
one
aspect of the present disclosure;
[0043] FIG. 19 shows an end view of an ice structure built in accordance with
one
aspect of the present disclosure;
[0044] FIG. 20 shows a side cross-sectional view of an ice log mounted in
another ice
log that is acting as a footer;
[0045] FIG. 21 shows a side cross-sectional view of the combined vertical
ice log and
footer with another ice log disposed on top of the vertical ice log;
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[0046] FIG. 22 shows a side view of an ice from formed out of ice longs which
have
been inserted into holes formed in other ice logs;
[0047] FIG. 23 shows a side view of an ice log having intersecting ice logs
extending
therethrough with icicles formed thereon;
[0048] FIG. 24 shows a cross-sectional view of two molds used from forming ice
beams;
[0049] FIG. 25 shows a front view of a cap for a mold having a projection
for forming
a hole;
[0050] FIG. 26 shows a side view of the cap of FIG. 25;
[0051] FIG. 27 shows a side view of an ice frame built using ice beams to
form a
framework which can be connected together without using slush;
[0052] . FIG. 28 shows a front view of the ice frame shown in FIG. 27;
[0053] FIGs 29, 31 and 32 show end views of caps which can be used to form and
end of an ice beam to facilitate its use in construction.
[0054] FIG. 30 shows a side view of the cap shown in FIG.. 29;
[0055] FIG. 33 shows the end view of beam formed using the cap shown in FIGs.
29
and 30;
[0056] FIG. 34 shows a top view and FIG. 34A show a side view of the beam of
FIG.
33 with a plurality of other beams disposed in the channels in the end;
[0057] FIGs. 35 and 36 show an end view and a side view, respectively, of the
end of
a beam made using the cap shown in FIG. 31;
[0058] FIG. 36 shows a side view of the beam of FIG. 36 with other beams
disposed
in the channel or slot;
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[0059] FIG. 37 shows a side view of a plurality of beams fitted together to
form a
support structure;
[0060] FIG. 38 shows a cross-sectional view of a mold having a projection
formed
therein for making a slot along the length of the ice beam.
[0061] FIG. 39 shows cross-sectional view of a mold having a sleeve
disposed
therein for making ice beams;
[0062] FIG. 40 shows a side view of a sleeve disposed in a mold;
[0063] FIG. 41 shows a side view of a wall formed by stacked ice beams;
[0064] FIG. 42 shows a side view of a method for thermally isolating the
water supply
tubes from the ice.
[0065] FIG. 43 shows a top view of FIG. 42;
[0066] FIG. 44 shows a top view of an alternate implementation of FIG. 42;
[0067] FIG. 45 shows an alternate configuration of a mold forming an ice beam;
[0068] FIG. 46 shows an alternate configuration of a mold for forming an ice
structure;
[0069] FIG. 47 shows the start of a tunnel formed by the ice beam formed from
the
mold in FIG 46 and a plurality of purlins;
[0070] FIG. 48 shows an alternate configuration of a mold for forming an ice
structure;
[0071] FIG. 49 shows a wall formed by ice beams made in the mold of FIG. 48;
[0072] FIG. 50 shows a side view of a partially build sound chamber;
[0073] FIG. 51 shows a top view of the base for a sound chamber;
[0074] FIG. 52 shows an external view of a sound chamber being formed; and
[0075] FIG. 53 shows a cross-sectional view of the sound chamber.
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[0076] It will be appreciated that the drawings are illustrative and not
limiting of the
scope of the invention which is defined by the appended claims. The
embodiments
shown accomplish various aspects and objects of the invention. It will be
appreciated that it is not possible to clearly show each element and aspect of
the
present disclosure in a single figure, and as such, multiple figures are
presented to
separately illustrate the various details of different aspects of the
invention in greater
clarity. Similarly, not all configurations or embodiments described herein or
covered
by the appended claims will include all of the aspects of the present
disclosure as
discussed above.
DETAILED DESCRIPTION
[0077] Various aspects of the invention and accompanying drawings will now be
discussed in reference to the numerals provided therein so as to enable one
skilled
in the art to practice the present disclosure. The skilled artisan will
understand,
however, that the methods described below can be practiced without employing
these specific details, or that they can be used for purposes other than those
described herein. Indeed, they can be modified and can be used in conjunction
with
products and techniques known to those of skill in the art in light of the
present
disclosure. The drawings and the descriptions thereof are intended to be
exemplary
of various aspects of the invention and are not intended to narrow the scope
of the
appended claims. Furthermore, it will be appreciated that the drawings may
show
aspects of the invention in isolation and the elements in one figure may be
used in
conjunction with elements shown in other figures.
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[0078] Reference in the specification to "one embodiment," "one
configuration," "an
embodiment," or "a configuration" means that a particular feature, structure,
or
characteristic described in connection with the embodiment may be included in
at
least one embodiment, etc. The appearances of the phrase "in one embodiment"
in
various places may not necessarily limit the inclusion of a particular element
of the
invention to a single embodiment, rather the element may be included in other
or all
embodiments discussed herein.
[0079] Furthermore, the described features, structures, or characteristics of
embodiments of the present disclosure may be combined in any suitable manner
in
one or more embodiments, or only some aspects may be included in an
embodiment. In the following description, numerous specific details may be
provided, such as examples of products or manufacturing techniques that may be
used, to provide a thorough understanding of embodiments of the invention. One
skilled in the relevant art will recognize, however, that embodiments
discussed in the
disclosure may be practiced without one or more of the specific details, or
with other
methods, components, materials, and so forth. In other instances, well-known
structures, materials, or operations may not be shown or described in detail
to avoid
obscuring aspects of the invention.
[0080] Before the present disclosure is disclosed and described in detail, it
should be
understood that the present disclosure is not limited to any particular
structures,
process steps, or materials discussed or disclosed herein, but is extended to
include
equivalents thereof as would be recognized by those of ordinarily skill in the
relevant
art. More specifically, the invention is defined by the terms set forth in the
claims. It
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should also be understood that terminology contained herein is used for the
purpose
of describing particular aspects of the invention only and is not intended to
limit the
invention to the aspects or embodiments shown unless expressly indicated as
such.
Likewise, the discussion of any particular aspect of the invention is not to
be
understood as a requirement that such aspect is required to be present apart
from
an express inclusion of that aspect in the claims.
[0081] It should also be noted that, as used in this specification and the
appended
claims, singular forms such as "a," "an," and "the" may include the plural
unless the
context clearly dictates otherwise. Thus, for example, reference to "a
bracket" may
include an embodiment having one or more of such brackets, and reference to
the
target plate" may include reference to one or more of such target plates.
[0082] As used herein, the term "substantially" refers to the complete or
nearly
complete extent or degree of an action, characteristic, property, state,
structure,
item, or result to function as indicated. For example, an object that is
"substantially"
enclosed would mean that the object is either completely enclosed or nearly
completely enclosed. Thus, a room with on opening for entry could be
substantially
enclosed. The exact allowable degree of deviation from absolute completeness
may
in some cases depend on the specific context, such that enclosing nearly all
of the
length of a lumen would be substantially enclosed, even if the distal end of
the
structure enclosing the lumen had a slit or channel formed along a portion
thereof.
The use of "substantially" is equally applicable when used in a negative
connotation
to refer to the complete or near complete lack of an action, characteristic,
property,
state, structure, item, or result. For example, structure which is
"substantially free of"
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a bottom would either completely lack a bottom or so nearly completely lack a
bottom that the effect would be effectively the same as if it completely
lacked a
bottom.
[0083] As used herein, the term "generally" refers to something that has
characteristics of a quality without being exactly that quality. For example,
a
structure said to be generally vertical would be at least as vertical as
horizontal, i.e.,
would extend 45 degrees or greater from horizontal. Likewise, something said
to be
generally circular may be rounded like an oval but need not have a consistent
diameter in every direction.
[0084] As used herein, the term "about" is used to provide flexibility to a
numerical
range endpoint by providing that a given value may be "a little above" or "a
little
below" the endpoint while still accomplishing the function associated with the
range.
[0085] As used herein, a plurality of items, structural elements,
compositional
elements, and/or materials may be presented in a common list for convenience.
However, these lists should be construed as though each member of the list is
individually identified as a separate and unique member.
[0086] Concentrations, amounts, proportions and other numerical data may be
expressed or presented herein in a range format. It is to be understood that
such a
range format is used merely for convenience and brevity and thus should be
interpreted flexibly to include not only the numerical values explicitly
recited as the
limits of the range, but also to include all the individual numerical values
or sub-
ranges encompassed within that range as if each numerical value and sub-range
is
explicitly recited. As an illustration, a numerical range of "about 1 to about
5" should
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be interpreted to include not only the explicitly recited values of about 1 to
about 5,
but also include individual values and sub-ranges within the indicated range.
Thus,
included in this numerical range are individual values such as 2, 3, and 4 and
sub-
ranges such as from 1-3, from 2-4, and from 3-5, etc., as well as 1, 2, 3, 4,
and 5,
individually. This same principle applies to ranges reciting only one
numerical value
as a minimum or a maximum. Furthermore, such an interpretation should apply
regardless of the breadth of the range or the characteristics being described.
[0087] Turning now to FIG. 1, there is shown a side view of two ice logs 4
formed in
accordance with principles of the present disclosure. The ice logs 4 may be
formed
by filling a sleeve 8 with water and leaving the filled sleeve at a location
which is
below 32 F or 0 C. Over time, the water will turn to ice which can then be
used for
forming structures.
[0088] In accordance with one aspect of the present disclosure, the sleeve 8
can be
formed from a thin, flexible material such as many plastics, such as
polyethylene.
The material can also be see-through so that the user can ensure that there
are no
large bubbles trapped inside the sleeve. Typically, the flexible sleeve will
be tied or
clamped off at one end, filled to the desired length and then the opposing end
tied
off or clamped.
[0089] As shown on ice log 4a, the end 8a of the sleeve may simply be tied off
by
knotting the end of the sleeve 8 to form end 4c of the ice log. In the
alternative, a tie
or clamp could be used to close the end as shown at end 4e on ice log 4b. The
use
of a thin, flexible material may allow the person making an ice structure to
cut the ice
log 4a to a desired length by the use of a saw, etc. as shown at end 4d on ice
log 4a
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(thereby exposing the frozen water 12). The sleeve 8 can then be stripped off
the
ice log 4 and the ice log used as needed.
[0090] According to one configuration, the person making the ice structure may
be
able to plan needed lengths and to know the dimensions of the piece
beforehand.
Culturing icicles, even by the use of a table, can be somewhat unpredictable
as
temperature, wind and flow patterns result in a variety of different shapes.
Water
has to be added at a flow rate which is fast enough that the water does not
freeze
before forming the icicle, but not so fast that the water flows over and melts
an
existing icicle. A strong breeze can cause the icicles for form at an angle,
and/or
can disrupt the flow of water to the growing icicle. A warm breeze can melt
back the
icicles, requiring that they be given additional time to grow to a desired
length. Very
strong winds can cause icicles to break off the structure from which they
hang.
[0091] In contrast, with the present disclosure the person making the
structure may
know that they will need 50 ice logs which are 10 feet long each. The person
can
then fill five 100-foot sleeves 8 having the desired diameter with water and
leave
them out to freeze overnight or for a couple of days depending on the
temperature.
As soon as the water is properly frozen a chainsaw can be used to quickly form
50
ice logs of the same length so that building may commence.
[0092] According to another configuration, the ice logs can also be formed
in an
industrial freezer or a refrigerated trailer if necessary and can be stacked
on shelves
to maximize the number of logs created in a small space. Because the water is
contained within the sleeves 8, the floor of the freezer will not be slippery,
and the
structural components of the ice structure can be pre-made. As soon as the
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temperature falls to a desired threshold, the ice logs 4 can be assembled into
the ice
structure and, if desired, sprayed with water to cover the ice structure in
icicles. This
may substantially speed up the process for forming the ice structures (such as
ice
castles/ice palaces), thereby allowing an attraction to be open earlier and
generate
larger revenues.
[0093] Another advantage of forming the ice logs in plastic sleeves is that
ice has a
tendency to freeze to other pieces of ice. If a number of pieces of ice are
stacked on
top of one another, it is not uncommon for the pieces to freeze together,
thereby
requiring pieces of ice to be broken off the other pieces of ice when it is
needed for
use. The plastic sleeves, however, tend to prevent or minimize the ice logs
from
freezing to each other. Thus, a large number of ice logs can be placed on top
of one
another (either for shipping or simply for convenience during use) with the
plastic
sleeves left in place so that ice logs do not freeze together. Once needed,
the log
can be moved into place and the plastic sleeve cut with a razor blade, etc.,
to
remove it from the ice log immediately before use.
[0094]
According to another configuration, the various load capacities of the
structure
can be calculated more readily. Because the ice logs will be substantially
solid ice,
the amount of weight which can be carried by an individual log over a given
span
can be more readily calculated than using a structure which forms more
randomly
and which is inconsistent from end to end, such as an icicle. For example, on
lake
ice, 3 inches of ice will support a person on foot, 4 inches will support a
group in
single file, while 7 1/2 inches will support a passenger car. In the present
disclosure
a balcony could be formed by placing a number of 4-inch diameter ice logs
adjacent
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one another and then running a sprinkler over the logs to create another inch
or two
of ice. While large diameter ice logs can be used for building structural
support,
smaller diameter ice logs can be used for providing a frame to grow icicles
and for
connecting large diameter ice logs for lateral support.
[0095] In some applications, such as where a specific three-dimensional
shape is
desired, the sleeve 8 could be formed from a more rigid plastic, such as
polyvinyl
chloride. In such configurations the sleeve 8 may include a port 20 (shown on
sleeve 4b of FIG. 1) and retainers 24 for holding opposing sides of the sleeve
together while the water freezes into an ice log. The sleeve 8 may also be
squared
off as shown at end 4F of ice log 4b.
[0096] A rigid sleeve could be made in a variety of shapes. For example, the
sleeve
may form a void which is generally helical in shape. The two halves of the
sleeve
could be held together with the retainer(s) 24 and filled with water. Once the
water is
frozen the two halves of the sleeve can be removed thereby leaving a helically
shaped ice log which can be used as a design element.
[0097] It will be appreciated that a variety of different dimensions of ice
logs may be
used. For example, a large balcony may be supported by ice logs having a 6-
inch or
8-inch diameter. In contrast ice logs could be made having a 2- or 3-inch
diameter
when being used as an initial structure for growing icicles and the like as
part of
design elements which have relatively minor loadbearing requirements.
[0098] The ice logs 4 may be preferred in some applications over wood or
steel
frames. When an "ice castle" is illuminated, a steel or wood frame may be
visible, at
least in shadow, and may lessen the aesthetic desirability of the ice castle.
In
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contrast, ice logs are typically translucent and, in many cases, transparent
thereby
allowing light to more readily flow through the design, improving the design's
aesthetics. In fact, icicles can entrain air as they are being formed, leaving
the icicle
with a cloudy appearance with partially obscures light. In contrast, as the
water
being used to form an ice log sits air bubbles tend to pass out of the water,
often
leaving the ice longs more translucent than many icicles. This can be
advantageous
for lighted ice structures.
[0099] Turning now to FIG. 2, there is shown an ice log 4g disposed in a
liner 8 in
the shape of a candy cane. The sleeve or liner 8 may be rigid, such as two
rigid
pieces being held together to hold the water as it freezes, or the liner may
be flexible
and simply moved into the desired shape once it has been filled with water and
the
ends tied off. Unlike the use of icicles, etc., the use of the liner or sleeve
8 allows for
a wide variety of shapes to be formed which may be used in the aesthetics of
the ice
structure being made. For example, if the ice structure is meant to replicate
Santa's
workshop, two candy cane-shaped ice logs could be disposed on either side of
the
door into the ice structure. While the candy cane-shaped ice log 4g could be
subjected to sprinklers spraying water so as to generate icicles, the ice log
itself may
be used as an aesthetic feature of the overall design of the ice structure. A
similar
shape could also be used as the runner for a sleigh.
[00100] The use of a flexible sleeve 8 is highly advantageous because the
shapes into which the ice logs are formed are up to the creativity of the
creator.
Additionally, a thin flexible sleeve which can be cut away is advantageous
because it
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is easy to remove the ice log from the sleeve regardless of its shape. All the
creator
needs to do is run a razor blade down the sleeve and pull the sleeve off the
ice log.
[00101] FIG.
3 shows an ice log 4h formed in an oval shape. The oval-
shaped ice log 4h could be used to form an oval-shaped room, either by being
placed adjacent the bottom of a number of ice logs extending vertically so as
to
anchor the ice logs in a desired pattern, or by resting on top of the vertical
ice logs
so as to create a continuous header around the room. Once the oval-shaped ice
log
4h is in place, the small opening 30 could be closed by filling the same with
snow or
slush and applying water. Of course, a number of ice logs 4h could be placed
front-
to-front so as to form a tunnel by simply applying a small amount of water to
freeze
the ice logs together. One advantage of this method of building an ice
structure is
that the person making the ice structure can form a footer and header for a
wall in
any desired shape. Instead of having to individually connect dozens of small
icicles
to form a wall, a single footer can be placed on the ground, vertically
extending ice
logs anchored thereto, and then a header placed along the tops of the
vertically
extending logs. Thus, for example, a wall 20 feet long and 10 feet high could
be
built with as few as 6-8 pieces of ice. The wall could provide a smooth
curvature or
other shape. In contrast, building such a wall from icicles may require dozens
of
icicles and multiple layers.
[00102] FIG.
4 illustrates an end view of a pair of arcuate ice logs 4i and 4j
forming a tunnel 34 and a pair of ice logs 4k and 41 being used to anchor the
arcuate
ice logs. Using the ice logs as anchors is relatively easy. The anchor ice
logs 4k
and 41 are simply placed adjacent to the base of the more vertically extending
ice
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logs 4i and 4j and snow or water is applied so that the ice logs freeze
together.
Vertically extending ice logs can also simply be disposed in place and have
snow
packed around their base. Because the ice logs can be cut or formed with a
flat
bottom, they are much easier to dispose in a vertical orientation than is an
icicle.
They can also be used as a footer over a length much longer than most icicles
and
are substantially consistent in dimension ¨ thereby making it easier to anchor
vertical ice logs into the footer than attaching icicles together would
typically allow.
[00103] FIG. 5 shows a support structure 38 formed out of ice logs
making
different shapes upon which icicles can be formed to produce a work of art or
part of
an ice castle. The structure 38 is formed by a first ice log 4n and a second
ice log
4o. Extending between ice logs 4n and 4o is a third ice log 4p and two short
ice logs
4q and 4r which are attached to one another so as to form an "X." The X shape
can
be used both aesthetically and structurally on the structure such as a design
element
or as a support frame for growing icicles. Disposed above the X shape is a
generally
oval-shaped ice log 4s and a diamond-shaped ice log 4t. The various ice logs
can
be attached to one another by the use of snow, slush or spraying with water
until the
structures freeze together. The design can be formed by bending the flexible
sleeve (not shown in FIG. 5) into the desired shape. Once the water has frozen
into
ice and the sleeve removed, the small gap left can be filled with ice or snow.
[00104] FIG. 6 shows a pair of ice logs 4 being subjected to sprinklers
42 or
another water spraying device so as to form icicles 46. As the water 50
contacts the
ice logs 42, the water freezes and gradually builds upon itself to create
random
icicles. It will be appreciated in accordance with the present disclosure that
the ice
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logs 4 could be used to form a structure in which all of the visible ice is
icicles 46, or
a structure which includes no icicles and is simply formed from ice logs. Most
commonly, the ice logs are used to allow the builder to create walkways and
other
structures which enhance the user experience by allowing the user to come
close to
a greater part of the overall structure. Either way, the ice castle or a
structure can
be enhanced by lighting the structure, particularly at night, as the ice logs
4 provide
minimal interference with light flow. Additional ice logs 4 can be added on
top of the
icicles 46 or other ice logs to further increase the size of the ice castle on
display.
[00105] Turning now to FIG. 7 there is shown an ice structure 60 built
from ice logs
4 (only some of which are marked) having a tunnel 64 and a set of stairs 68
leading
to a second story balcony 72. Some of the ice logs 4 are disposed generally
vertically so as to form support pillars, while other support logs are
disposed
generally horizontally to form steps, beams connecting the support pillars and
supporting the ice logs forming the balcony 72. Still other ice logs can be
disposed at
angles between vertical and horizontal. These intervening ice logs may be used
for
structural support and/or as a support frame for growing icicles if all or
part of the ice
structure 60 is sprayed with water.
[00106] It will be appreciated that the use of the ice logs in accordance
with the
principles of the present disclosure allows substantial creativity on the part
of the
builder of the ice structure. The sleeves 8 can be used to make a wide variety
of
shapes in the ice logs, thereby allowing for a wide variety of designs. For
example,
stairways can be curved. A number of wavy ice logs could be frozen together to
form a wavy slide down from a balcony. Walls formed from nothing but ice logs
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could be used, or the ice logs can be covered with icicles by spraying water
over the
ice logs. Tunnels of various shapes and sizes can be formed. Additionally, the
ice
logs can be formed in such a way that electrical cables or lighting could be
disposed
within the ice logs thereby ensuring that they would not present a tripping
hazard to
patrons of an ice castle display. (An image of such ice logs in shown in FIG.
13)
[00107] FIG. 8 shows a top view of a house 80 having a number of rooms 84
and
a second story with a balcony 86 formed in accordance with principles of the
present
disclosure. It will be appreciated that the entire house could be built out of
ice logs.
The ice logs could be either translucent or nearly transparent to thereby
conduct
light through the house. If multiple different lights are used, the house
could be
designed to change colors as the attendees walked through the house. If
desired,
the house could even be structured so as to accommodate sleeping arrangements,
thereby allowing the "ice house" to function as a hotel. Likewise, a
restaurant could
be made where the structure is nearly completely made of ice.
[00108] FIG. 9 shows a cross-sectional view of an ice log 4m which is used
to form
a base or footing. The ice log 4m is formed by taking a sleeve eight and
filling it
partially with water so as to form a flattened ice log. The ice log 4m can be
made at
a remote location. However, there are advantages to forming the ice log 4m at
a
location in which it will serve as a base for building an ice castle/palace.
The bottom
of the ice log is flattened due to the partial filling of the sleeve 8. When
formed in
place the bottom of the ice log conforms to the ground 90 on which the ice log
is
formed. Thus, if the ground is uneven or sloped the ice log 4m will be
properly
positioned in place. By allowing some air into the sleeve 8 an air pocket 94
can be
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left. This results in a base which has a flat top surface. If desired, this
flat surface
can be used to build structures or otherwise receive other ice logs. It will
be
appreciated that ice logs can be made with flattened services facilitate
building a
variety of different designs.
[00109] Once the ice log 4m has frozen, the sleeve 8 may be cut away. The
portion of the sleeve between the ice log 4m and the ground 90 may be left in
place
or may be slid out as desired. The base formed by the ice log 4m is highly
desirable
as it facilitates the rapid building of ice structures. As shown in FIG. 10,
the base
formed by ice log 4m can have one or more pockets or holes 96 cut in. This can
be
accomplished with an auger or a chainsaw. The pockets or holes 96 may extend
partially into or all the way through the ice log 4m. Other ice logs 4 may be
inserted
into the holes and slush and/or water can be poured into the holes 96 to
freeze and
thereby anchor the other ice logs into ice log 4m. If the holes are formed
only
slightly larger than the cross-sectional area of the other ice logs 4, the
side wall
defining the holes can be used to hold the other ice logs in vertical or other
orientations even while the slush on or water poured and the holes freezes.
This is
highly advantageous as it allows an ice structure to be built in a relatively
short
amount of time.
[00110] While shown laying on the ground, it will be appreciated that ice
log 4m or
even a more cylindrical ice log can have holes drilled in to allow the
insertion of other
ice logs for the building of intricate structures. For example, an ice ladder
could be
formed in such a way that the rungs of the ladder formed by ice logs are
securely
held within larger ice logs on either side.
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[00111] FIG. 11 shows a flowchart for forming ice logs in accordance with
principles of the present disclosure. The first step is to select a sleeve.
The sleeve
may then be filled with water. The water filled sleeve is then subjected to a
temperature below freezing (i.e., below 32 F or 0 C). Once the water has
frozen, the
sleeve is removed from the frozen water which forms an ice log for building an
ice
structure. While the sleeve could be warmed to help slide the sleeve off the
ice log,
this is a time-consuming process and releases a wet ice log which must be
handled
carefully so that the builder's hands do not freeze to the log. In contrast,
the flexible
sleeves in accordance with the present disclosure prevent the logs from
freezing
together and can be quickly removed without needing to apply head to unfreeze
the
outer surface of the ice log.
[00112] FIG. 12 shows a flowchart for building an ice structure in
accordance with
principles of the present disclosure. The first step is to select a plurality
of ice logs.
The ice logs are placed in close proximity and snow, slush, or water is
applied to the
ice logs at a temperature below 0 C or 32 F so as to connect the ice logs by
ice. In
building the ice structure, a plurality of the ice logs will be disposed
generally
vertically, and a plurality of ice logs will be disposed generally
horizontally and
attached to the generally vertically ice logs with snow, slush, or water and
allow
them to freeze. The method may include disposing a plurality of ice logs so as
to
form the floor of a second story of the ice structure, or as a second story
balcony.
[00113] The method may further include spraying the ice logs so as to
develop
icicles on the ice logs. The method may further include adding additional ice
logs to
the initial ice logs and/or icicles in order to increase the size of the
structure.
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[00114] As has been partially discussed above, the of use flexible sleeves
to form
ice logs has numerous advantages. The ice logs may be clearer and stronger
than
conventional icicles as the water freezes into a log having a substantially
consistent
diameter and are not reliant on dripping water to form. The ice logs can be
grown
much larger in a shorter amount of time, and the creator has much greater
control
over the end product. For example, one company making ice structures from
icicles
claims that it places more than 1000 icicles a day to build its structures.
Those
icicles would typically be a variety of shapes and sizes. In contrast, in the
present
disclosure the person forming the ice logs can accurately produce a given
length of
ice logs of diameter a, and another given length of diameter b, and still yet
another
length of diameter b as required.
[00115] Rather than using thousands of icicles which are 2-3 feet long and
tapering from one end to another, the present system allows large structures
to be
built using large ice logs. For example, a center log for a large attraction
could be
desired at 9 inches in diameter and 15 feet tall. Creating such an icicle
would be
extremely difficult as the weight of the icicle may cause it to break off of
the structure
from which it depends long before the icicle reached such a length or girth.
In
contrast, such an ice log can be formed by simply selecting a 9-inch sleeve
which is
about 16 feet long, tying off one end of the sleeve, filling it with water and
tying off
the opposing end. The ice log can be made in a commercial freezer or left
outside
to freeze in ambient air. When needed, the sleeve may be simply cut off and
the ice
log used. (The sleeve could also be left on if desired). Prior to removal, the
sleeve
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reduces the risk of ice logs freezing together, thereby facilitating transport
and
stacking at the location of the attraction.
[00116] Hundreds of ice logs of smaller diameters can be formed overnight
if
temperatures are sufficiently cold, or over a couple of days at warmer
temperatures.
For example, ten sleeves 100 feet long and four inches in diameter can be used
to
make 50 20-foot ice logs or 100 10-foot ice logs which are all substantially 4
inches
in diameter. Thus, it is much easier to plan out an ice sculpture because the
person
making the ice logs knows exactly what he or she will get.
[00117] Less water is wasted as the sleeve keeps all of the water
necessary to
form the ice log within the sleeve, rather than dripping onto the ground as
only some
of the water freezes to make an icicle. Likewise, the creator of the ice
structure can
mold the ice logs into desired shapes and can be easily removed from the
sleeves
when needed, but stored in the sleeves prior to use to prevent the ice logs
sticking
together. The sleeves also help prevent braking if two ice logs get banged
together.
[00118] Turning now to FIG. 13, there is shown an ice log 4s formed in
accordance with another aspect of the invention. Instead of simply placing
lighting
or other powered lines behind various ice formations, the ice log 4s is formed
by
placing a powered line 102, such as a line having lights 104, in the sleeve 8.
One
end 4d I tied off and the sleeve filled with water. The other end 4c is then
tied off.
The water in the sleeve 8 is then frozen and the sleeve removed. The resulting
ice
log 4c has a power line inside (which could be used to power various
attractions
and/or to light the ice log. It will be appreciated that lighting behind a
structure tends
to pass the same color of light through the adjacent structures. By having the
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lighting inside the log, however, individual logs could be provided with
different color
lights, or could change color in sequence.
[00119] Turning now to FIG. 14, there is shown a slide 110 made from a
plurality
of ice logs 4. Because long ice logs can be formed quickly, within a day or
two, a
slide could be formed by building a structure and then placing long ice logs
for form
the slide surface. Larger ice logs could be used on the sides to prevent the
user
from falling off the slide. The slide could be added to a balcony, or could
simply
have a staircase.
[00120] FIG 15 shows an alternate configuration of an ice log 4t which
could be
used for a slide so that the slide has a waive like surface. This can be done
by
simply laying of the water filled sleeves so that the sleeves curve. As soon
as the
water in the sleeve freezes, the ice logs can be used to make a wave shaped
slide.
[00121] FIG. 16 shows an alternate construction method. While cutting
holes in
the ice log 4m which forms the base or footing is desirable, it is not
necessary. By
filling the sleeve 8 only part way with water, the top surface of the ice log
4m will be
generally flat and an air gap 84 may be left between the top surface of the
ice log
and the sleeve. When all or a portion of the sleeve 8 is cut way, the flat
surface of
the ice log 4m is available for attaching other ice logs thereto. The flat
surface of the
ice log 4m facilitates a vertical ice log 4 from being disposed on the
base/footer
formed by ice log 4m by simply placing the end of the ice log 4 on the base.
If the
bottom end of the ice log 4 and the upper surface of the ice log 4m are
sufficiently
flat and of sufficient diameter, the ice log 4 may remain in place without any
bracing,
support, etc. Water or snow can then be added to freeze the two ice logs
together.
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[00122] It will be appreciated that ice log 4m in FIG. 16 has a rounded
lower
surface 4m', unlike the lower surface of the ice log 4m shown in FIG. 9. This
can be
accomplished by forming the ice log on snow, which will give way to the weight
of
the water, while the ice log 4m in FIG. 9 is characteristic of a partially
filled sleeve
made on solid ground.
[00123] Turning now to FIG. 17, there is shown an alternate method for
attaching
ice logs 4 to the ice log 4m forming the base/footing. The ice log 4m may be
allowed
to freeze part way so as to leave a pocket of water 98. The sleeve 8 may be
partially or completely removed, and a hole cut in the upper surface of the
ice log 4m
sufficient to insert another ice log 4 into the pocket of water 98. If the ice
log has not
been left long enough that the bottom is frozen, the pocket of water 98 can be
drained off by removing the sleeve or puncturing the sleeve if desired. If the
lower
portion of the sleeve is left in place and not punctured or the bottom of the
ice log
has frozen solid, the water is then allowed to continue to freeze, thereby
anchoring
the ice logs in the base/footing. The pocket left by any water which does
escape
may also be filled in by over-spay. If necessary, vertical ice log 4 may be
held while
the water continues to freeze. This can be done by external support and/or
snow or
slush can be packed around the juncture of the two ice logs and allowed to
freeze
solid.
[00124] It will be appreciated that the technique for inserting the logs
can be used
for a variety of purposes. For example, a ladder of ice could be made by
cutting into
partially frozen logs and inserting a number of rungs, and then inserting the
opposing ends of the rungs into another frozen or partially frozen ice log.
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[00125] It will be appreciated that inserting an ice log into a pocket in
another ice
log allows for a substantially stronger juncture than simply applying slush or
snow
amount the end allowing that to freeze. The pocket can provide substantial
lateral
support, which and prevent an ice log from braking off of an ice log to which
it is
attached. This also allows for building at an accelerated rate. For example,
depending on ambient temperature, buildings two or more stories tall can be
built in
a single day. Likewise, this mechanism for inserting facilitates stronger
joints and
less waste of water as less ice needs to be added simply to hold the pieces of
ice in
place.
[00126] Turning now to FIG. 18, there is shown an alternate application of
aspects
of the present disclosure. As mentioned previously, the use of ice logs allows
for
rapid building. Not only can the pockets 96 be formed in the ice log 4m
forming the
base or footing, but pockets 96 can also be formed in ice logs 4u which form a
header. The pockets 96 allow the top end of the vertical (or other
orientation) ice
logs to be inserted into the ice log 4u. (The outlines of the pockets 96 have
not been
shown in the middle horizontal ice log 4u which acts as a base for the top row
of
vertical ice logs and as a header for the bottom row or vertical ice logs for
the sake
of clarity but may be present to gain the advantages discussed herein)
Inserting the
end in a sufficient distance (i.e., 3-4 inches) provides virtually instant
stability to the
ice log 4u on top of the ice logs 4. Preferably the pockets are only slightly
larger
than the diameter of the vertical ice logs 4 so that the ice logs almost nest
in place.
Slush or water can be placed in the pockets just before attachment to promote
the
vertical ice logs and the header ice log 4u from freezing together.
Additionally, if
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structure is over-sprayed with water, the freezing water also freezes the
various ice
logs together. However, the simple engagement of the top of the ice log in the
pocket instantly prevents the vertical ice log from simply rolling off and
avoid the
need for someone to stand there and hold it in place while slush freezes
sufficiently
to hold the ice logs together.
[00127] Because the header ice logs 4u are already generally stable when
placed
on the vertical ice logs 4, the next layer of vertical ice logs can be added
much
sooner. There is no need to coat the ice logs over night with water to build
up
sufficient mass to hold the weight of the next level as is done when building
with
icicles. Additionally, the use of the pockets 96 facilitates the use of
powered lines
102. Once the pocket 96 is formed, a drill can be used to form a small hole
through
to the exterior of the ice log or the powered line can be passed out of a
small gap in
the pocket 96 between the generally horizontally extending ice logs 4m, 4u and
the
vertical ice logs 4. The lower lines 102 can be connected together and then
power
supplied to, for example, light up multiple ice logs from inside the ice logs.
This
provides a more brilliant effect than simply backlighting, and ice logs can be
made to
provide individual colors or combinations of colors. For example, one ice log
could
light up blue, while the next is green, the next is yellow and the next is
purple.
Patterns could be formed in the structure by regulating when a given color is
being
shown in each ice log.
[00128] While shown in FIG. 18 as relating to vertical ice logs, it will
be
appreciated that the use of pockets could be done with a variety of different
ice log
shapes and orientations. For example, instead of vertical ice logs on the
second
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layer, pockets may be used to hold ice logs used for lateral bracing between
adjacent vertical or horizontal ice logs. Likewise, a row of semicircular ice
logs 4i
could be used to form a tunnel by attaching to adjacent header ice logs 4u as
shown
in FIG. 19. Furthermore, the structures shown in FIG. 5 could be attached
using
pockets to facilitate attachment beyond simple surface attachment with a
coating of
ice.
[00129] FIG. 20 shows a side cross-sectional view of an ice log 4 mounted
in
another ice log that is acting as a base/footing. The ice log 4m may be
allowed to
freeze almost all of the way or may be completely frozen. An auger or similar
tool
can then be used to cut a hole in the ice log 4m. Preferably, the hole formed
by the
auger, etc., is only slightly bigger than the ice log 4 which will be inserted
into the
hole vertically. If the ice log 4m has not completely frozen, the bottom of
ice log 4
will displace the water and may force it upwardly between the ice log 4 and
the
sidewalls of the hole formed in ice log 4m. Sidewalls of the hole hold the ice
log 4 in
place so that the water can freeze ¨ thereby bonding the two ice logs
together.
Because the thickness of the ice log 4m acting as the base/footing, the
vertical ice
log 4 does not need to be held in place while the water freezes, and slush is
not
required to bond the two structures together.
[00130] While an air pocket 94 may be left at the top of the ice log 4m
forming the
base/footing and under the sleeve 8, such is not necessary as the hole in the
ice log
4m holds the vertical ice log in place. The ice logs and then be over-sprayed
with
water to strengthen the attachment. A worker, however, does not need to pack
slush around the ice log 4 and need not hold it is place while the slush
freezes.
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[00131] FIG. 21 shows a side cross-sectional view of the combined vertical
ice log
and footer similar to FIG. 20 in which the two have frozen together. One end
4z of
the ice log 4 has been provided with a concave surface 104. This may be
accomplished by using a router, a sander, or even a heat source applied to the
end
of the ice log. The concave surface 104 provides a cradle or channel into
which
another ice log may rest in a more stable orientation than trying to place an
ice log
with a convex outer surface on a flat top. A v-shaped surface could also be
provided
by simply making two cuts with a chain saw while cutting a larger ice log. The
area
which is not filled by the ice log 104 allows water to pool and then freeze
the two ice
logs together.
[00132] FIG. 22 shows a side view of an ice frame, generally indicated at
106,
formed out of ice logs which have been inserted into holes formed in other ice
logs.
Ice log 4m has a plurality of holes 108 formed therein. The holes 108 may
extend
completely through ice log 4m or may extend only part way. The sidewalls of
the
holes 108 help hold the vertical ice logs 4 in place and if cut properly no
slush is
needed. Additional support to the ice logs 4 is provided by one or more
intersecting
logs 4v which may extend into or through holes 112 in one or more of the
vertical
logs 4. Thus, a single intersecting ice log 4 can be placed between two ice
logs, or
a single intersecting ice log can extend through a number of ice logs 4. The
intersecting ice logs 4v provide support for the ice logs 4 and provide a
structure for
icicles to form when the ice frame 106 is over-sprayed with water. The
intersecting
ice logs 4v may even extend beyond the ice logs 4 to allow for additional
decorative
icicles to form therefrom, or to be used to attach other items. It will be
appreciated
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that the ice logs 4 may include additional holes 116 to allow intersecting ice
logs 4v
to extend in multiple directions. This allows the frame 106 to be held
together solidly
in three-dimensions without the use of slush and facilitates a strong bond
between
the ice logs as the frame 106 is over-sprayed with water. It also allows an
easy
location for decorative icicles 120 to grow as shown in FIG. 23 without the
use of
slush.
[00133] FIG. 24 shows a cross-sectional view of an alternate method for
forming
ice in accordance with the present disclosure. Rather than using a flexible
sleeve,
an elongate semi-flexible or generally rigid mold 130, 134 can be used. The
molds
may have a generally rectangular cross-section, though the bottom end thereof
may
be slightly narrower than the top both to allow the molds to be stacked and to
facilitate the removal of ice therefrom. It will be appreciated that if the
mold material
¨ such as plastic or metal is only semi-rigid the molds 130, 134 can be flexed
slightly
to help remove the water 138 after it has frozen into and ice beam.
[00134] The molds 130, 134 are filled with water 138, which is then
allowed to
freeze. The molds form pieces of ice similar in shape to a wood beam and the
ice is
thus referred to as an ice beam ¨ meaning that one or more sides are generally
flat,
as compared to an ice log which is generally rounded.
[00135] The molds 130, 134 may be made from metal or durable plastic or
polycarbonate materials and reused each year. Thus, a large number of molds of
desired sizes may be used, e.g., 4 feet, 8 feet, 10 feet and 12 feet, etc.
Alternatively, the molds 130, 134 could be made from relatively inexpensive
materials such as extruded plastic or polycarbonates in very long pieces and
then
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cut with the ice beam to a desired size by a chain saw etc., as discussed
above.
The cut pieces of the molds 130, 134 can be stacked upon each other with the
molds helping to prevent the ice beams from freezing to other ice beams.
[00136] Also shown in FIG. 24 is a light string 102 and light similar to
that shown in
FIG. 13. The lights may be held in place while the water turns to ice so that
a
resulting ice beam can be lit from the inside.
[00137] It will be appreciated that the molds may be integrally formed with
an end
to hold the water in. Alternatively, a removeable end cap may be used. FIG. 25
shows a front view of a removable end cap 140 for one of the molds which has a
propection144. The projection 144 is used to form a hole in the end of a beam
formed by freezing the water 138. The hole in the beam is designed to receive
an
ice dowel or spike. Other projections may be included along the mold to form
additional holes in the ice beam or holes can be formed by drilling etc.
Because the
ice beams are generally flat on each side, they can be stacked one upon the
other
more securely without the need for slush. Additionally, ice dowels ¨ which may
be
0.5 ¨ 2 inches in diameter, can be inserted into the holes in various ice
beams to
hold the beams more securely in place while they are over-sprayed by water.
[00138] The end caps 140 may be adhesively attached to the remainder of the
mold, attached mechanically, such as by friction or a clip, or may be formed
integrally with the mold and then cut off to allow the ice beam to come out.
[00139] The ice dowels provide additional shear strength between adjoining
ice
logs as shown in FIG. 27. The ice beams 154 can be stood upon the footers
154m.
An ice dowel 150 may be used to help hold the ice beams 54 and 154m in the
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proper orientation with one another. The ice dowels 150 can also be used to
secure
the ice beams 154 with the ice beam header 155u. A plurality of purlins 154y
can
extend between the headers 154u. Some purlins 154y can be larger than others
to
provide additional support for the vertical ice beams 154. When over-sprayed
with
water, the ice beams form a very strong bond which hold the frame of the ice
structure together without the need for slush.
[00140] Turning now to FIG. 29, there is shown an end view of end cap 140
which
has a projection 144 which is generally in the shape of a cross. FIG. 30
provides a
side view of the end cap 140 and projection 144. FIG. 30 also shows a handle
158
which may be used for attaching or removing the end cap 140 to the mold (not
shown).
[00141] FIGs. 31 and 32 show alternate end caps 140 having projections 144
which will shape the end of the ice beam formed in the mold with which the end
cap
is associated. The projections 144 may be sufficiently long that they form a
channel
extending into the end of the ice beam. This allows a channel or slot to be
left in the
top of the ice beam formed in the mold. As will be discussed, the slots
facilitate
adding together ice beams in a secure and efficient manner.
[00142] FIG. 33 shows an end view of an ice beam 154 formed using the end
cap
in FIG. 29. The ice beam 154 is left with a pair of intersecting channels 170.
In
other words, there are a number of projections 172 sticking out the end. Both
the
channels 170 and projections may be fairly flat on the sides. As shown in
FIGs. 34
and 34A, this allows a number of ice beams 164 to be placed in the slots and
extend
from the ice beam 154. The ice beams 164 may be butted against one another and
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may nest in the slots 170 so even a small amount of water poured on joints
between
the beams 154 and 164 will enable all of them to be frozen together. No slush
is
required, and the five beams quickly form a continuous mass of ice. It will
also be
appreciated that a single ice beam 164 could run through one of the channels
170 in
one direction with the other two ice beams 164 are secured thereto and to the
ice
beam 154. The channels or slots 170 may be of a depth so that the tops of the
beams 164 rest generally even with the tops of the projections 172 as shown in
FIG.
34A. Alternatively, the beams 164 may extend above the projections to
facilitate the
attachment of additional ice beams in a vertical orientation. For example,
another
ice beam (not shown) having a similar end could be turned upside down and its
slots
aligned the ice beams so that the projections 172 of the two similar ice beams
touch
or nearly touch and then water added so as to form a longer ice beam 154 with
ice
beams 164 coming out the middle. A small sprayer or simply a couple of water
could be used to add water either just before attachment or just after to
facilitate the
ice beams freezing together.
[00143] FIGs. 35 and 36 shown an end view and a side view, respectively,
of the
end of an ice beam 154 made using the cap 140 shown in FIG. 31. The slot 170
left
in the end of the ice beam 154 may receive a single ice beam or a pair of ice
beams
with their ends disposed in the slot. A small amount of water will freeze the
ice
beams together. Because of the thermal mass of the ice beams 154, etc., the
water
will freeze very quickly. As with the embodiment shown in FIG. 34, the other
beams
could extend beyond the projections 172 of ice beam 154 so that another ice
beam
154 could be added on top. It will be appreciated that the slots could be, for
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example, from 1 to 4 inches wide. The advantage of a wider slot is that the
ice
beam disposed therein is larger and can thus support the weight of a person
while
building. For example, an ice beam which is 4 inches wide and 6 inches tall
can
easily support even a large man. This enables the structure to be built much
more
quickly than ice icicles and in many cases even ice logs.
[00144] FIG. 37 shows a structure built from the ice beams 154 and 164.
Because
the ice beams and be fit and frozen together very quickly, the structure can
be built
is considerably less time than when made with icicles or even ice logs. The
ice
beams provide support for one another and their relatively large size allow
any water
poured thereon to freeze very quickly because of the thermal mass.
Additionally, the
size of the ice beams can support hundreds or even thousands of pounds of
weight,
with each ice beam being supported by another ice beam including in 3
dimensions.
[00145] In addition to an ice beam 154 being made to have slots in the
ends, one
or more slots may be formed along the length of the ice beam so as to
facilitate the
attachment of other ice beams or ice logs. FIG. 38 shows a cross-sectional
view of
a mold having a projection 180 formed therein for making a slot along the
length of
the ice beam when the water 138 freezes. The projection may extend along the
entire length of the mold or may be only for a small portion. Likewise,
multiple
projections could be used to form an ice beam having a plurality of notches
formed
therein found mounting other ice beams.
[00146] FIG. 39 shows an alternate method for creating the ice beams which
is
somewhat a hybrid between the methods previously discussed for making ice logs
and that for making ice beams. It has been found to be advantageous to dispose
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sleeves 8 in the molds 130 used to make the ice beams. The sleeves 8 easily
conform to the shape of the mold and help to make the ice beam easier to
remove
from the mold after the water 138 has frozen. They also allow the molds 130 to
be
used without being watertight. Thus, for example, 10 molds of 15 feet in
length can
be put end to end and then a 150-foot sleeve can be placed in the molds and
filled
with water. The desired ice beam in formed, while allowing ease of handling
and
better portability for the molds. Curved molds could also be used to provide
precise
shapes if desired and beams could even be formed at a right angle.
[00147] It also allows stacking of the ice beams with less risk of the ice
beams
being frozen together. Thus, the sleeve allows substantially all of the
benefits of ice
logs with all of the geometric benefits of flat side(s) which the molds
provide to the
ice beams. Additionally, end caps are not needed for these ice beams. The
sleeve
8 is simply disposed in the mold and with one end tied off (before or after
placement
in the mold). The sleeve 8 is then filled with a hose, etc., to the desired
height and
the opposing end tied off. This may be within the mold or sticking out as
shown in
FIG. 40. Once frozen, the ice beam is pulled out of the mold and cut into the
desired
sizes. Where end caps are used, it will be appreciated in light of the present
disclosure that the sleeves 8 will facilitate removal of the end caps from the
ice
beam.
[00148] FIG. 41 shows a side view of a wall formed by stacked ice beams
154,
which may include pieces extending in multiple directions:. Unlike icicles or
ice
logs, the ice beams can simply be stacked upon one another to form walls or
other
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structures because of their flat sides. This can also facilitate making
buildings out of
ice.
[00149] One challenge when spraying water over ice from sprinklers is that
the
taller one extends the tubing with the sprinkler 182, the more likely the
tubing is to
bend to one side or the other. This is shown on the right side of FIG. 42. The
sprinkler tubing 180 leans to one side and makes the spray pattern less
reliable.
Additionally, the water is more likely to drip from the sprinkler than be
sprayed
properly over the structure. The droplets of water take longer to freeze than
the very
small drops normally sprayed by the sprinkler. The drops may be large enough
that
they melt the ice as they drop. Thus, it is not uncommon to look directly down
from
the sprinkler and to see a void going all the way to the ground in which there
is no
ice. Additionally, the tubing 180 can lean against the ice and melt its way
through
the ice.
[00150] In accordance with one aspect of the present disclosure it has
been found
that it is best to thermally isolate the tubing 180 from the ice 154. As shown
in FIGs.
43 and 44, this may be accomplished by placing an insulator 190, such as
chicken
wire 192 (FIG. 43), an l-bolt 194 (FIG. 44) a screen or some other structure
about
the tubing 180 which allows water to pass but holds the tubing in position. An
opposing end of the insulator 190 may be attached to the ice 154 of the ice
structure. This can be done by slush or by simply running a sprinkler over the
top.
The insulator will hold the tubing vertical, thereby reducing dripping. It
will also
separate the tubing from the ice, so that if there is water running along the
tubing
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180, the water will not melt the ice. Instead, it is given additional space to
either
freeze or travel to the ground.
[00151] Turning now to FIG. 45, there is shown an alternate configuration
of a
mold 130a. The mold has an outer wall is formed so that a void within the mold
has
portions which are disposed at a right angle to one another. The mold 130a may
be
filled with water directly and frozen, or a sleeve can be placed in the mold.
The
resulting ice beam is formed at a right angle. Such an ice beam can be used
for a
variety of situations. The ice beam can simply be placed so that the upper end
rests
against an existing ice structure to instantly form the framework of a tunnel.
Alternatively, when stacking beams to form a house, etc., the right-angle beam
can
be used in corners to provide additional strength without having to wait for a
substantial amount of water to freeze. Thus, for example, a first layer of ice
beams
could be placed end perpendicular to one another to form a corner. They could
have water sprayed on them and then the ice beam made from the mold of FIG. 45
placed on top of the other two. The corner is thus instantly strengthened over
what
would be provided by abutting logs and allowing water to freeze over them.
[00152] Turning now to FIG. 46, there is shown a mold 130b in the shape of
a
pentagon so that the void formed by the sidewalls of the mold has five
portions
which are angularly offset from one another. A sleeve 8 is disposed inside and
filled
with water. The sleeve 80 may be placed to cover the entire pentagon shape or
only
a portion. It then freezes into a shaped ice beam. FIG. 47 shows a tunnel
being
constructed from three ice beams 154a which are connected together by purlins
154y. Because of the thermal mass and slope of the ice beams 154, the purlins
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154y may stay in place by simply spraying the ice beam with water and then
placing
the purlins on top. The structure can then be sprayed with water to have
icicles
develop and finish off the tunnel. This allows the tunnel to be formed more
quickly
that prior art methods which requires laboriously attaching icicles together
and
gradually developing a tunnel shape.
[00153] Turning now to FIG. 48, there is shown an alternate configuration
of a
mold 130C. The mold has a sidewall disposed so that the void defined by the
sidewall is T shaped. Thus, a beam formed therein is generally T shaped. It
will be
appreciated that if it desired to dispose the water in a sleeve, a specialty
sleeve
having a T shape would be needed. Such may be used, or a piece of plastic can
simply be used to line the inside of the mold 130c to facilitate the release
of the
beam of ice once the water has frozen. The mold could also be sprayed with oil
or
some other hydrophobic material to promote release of the ice beam once it is
frozen.
[00154] FIG. 49 shows a plurality of ice beams 154b formed from the mold
130c
mounted in a footer 154m. The ice beams 154b can be placed end to end and then
over sprayed with water. The last beam 154b on the right is disposed at a 90-
degree angle to the others, so as to form a corner. By connecting the ice
beams
154b to the footer 154m, a wall can be constructed very quickly and may stand,
for
example, 8-10 feet high.
[00155] Additionally, it is easy to place two rows of such ice beams and
then add
purlins connecting them thereby forming a tunnel. Thus, the entire
substructure of
the tunnel can be formed before the first overspray with water. Because time
is so
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critical when building ice structures, the use of ice beams and ice logs are
highly
advantageous. The ice logs or ice beams are minimally affected by wind or
extremely cold temperatures. Additionally, they allow building of the ice
structure
much more quickly. For example, if the holes 96 are only slightly bigger than
the ice
beams 154b, the ice beams can be placed in the footer 154m and purlins can be
added on top of the ice beams prior to the application of any overspray to the
structure. This allows workers to continue to build without being sprayed with
water
or having to handle slush, either of which can increase the risk of
hypothermia. This
allows the ice structure to advance at a rapid pace, thereby facilitating
display to the
public shortly after the ice structure was begun. In areas with short cold
seasons,
this could mean the difference between an ice structure being profitable and
losing
money.
[00156] Turning now to FIG. 50, there is shown a method for forming a
sound
chamber out of ice. Certain room structures are known for carrying sound
particularly well. This can be accomplished in an ice structure by forming a
base of
ice logs of ice beams. As shown in FIG. 50 a number of ice beams 154 are
disposed to form an elevated base 198 which is polygonal or generally
circular. FIG.
51 shows a top view of the formation of a base 198 from a generally circular
ice log
4w supported by a number of vertical ice logs 4x. A gap 199 is left to
facilitate the
formation of a door.
[00157] A mold, such as a very large beach ball 200 or a domed shaped tent
is
disposed in the opening and then over sprayed with water. The ice 202 formed
by
the water freezing on top of the mold progresses down and covers the ice logs
or ice
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beams 154 as shown in FIG. 52. The mold 200 is then collapsed leaving a room
which has an almost perfectly spherical ceiling as shown in FIG. 53. When a
person
whispers facing one wall, a person standing adjacent the opposing wall can
hear
what is being said.
[00158] Thus, there is disclosed a method for creating an ice structure.
It will be
appreciated that numerous modifications may be made without departing from the
scope and spirit of this disclosure. The appended claims are intended to cover
such
modifications.
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