Ice machine

Abstract

To provide a method for manufacturing an ice maker.SOLUTION: An ice maker includes a dry compartment and a wet compartment located adjacent to the dry compartment and including an evaporator case sized to receive an evaporator. The evaporator case includes: a plurality of interior panels which is joined to each other with snap-fit joints and in which each of the snap-fit joints includes a tab and defines a slot and each of a plurality of seams formed between the interior panels defines a foam-tight seal and a water-tight seal; and a plurality of exterior panels, each of which is joined to a mating interior panel of the plurality of interior panels with slide joints. The evaporator case is integrally insulated with blown foam insulation positioned between each of the plurality of exterior panels and a corresponding interior panel.SELECTED DRAWING: Figure 5A

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 62 / 714,414, filed August 3, 2018, and U.S. Provisional Patent Application No. 62 / 714,412, filed August 3, 2018, both of which are specifically incorporated herein by reference in their entireties.

[0002] The present disclosure relates to ice making machines. More specifically, the present disclosure relates to ice makers and storage containers, especially ice making machines having ice makers incorporating snap-fit ​​or slide-fit evaporator case assemblies with integrally formed components, and more streamlined cleaning methods thereof. [Background technology]

[0003] A typical ice maker, especially a commercial ice maker configured to make large amounts of ice for hours, days, and years at a time, has at least four circuits, not considering the structure of the ice maker itself: a cooling circuit for circulating a refrigerant, an air or water circuit for circulating chilled air or water in the cooling circuit, in some embodiments as part of the cooling circuit, a water circuit for circulating water for forming ice and sometimes for cleaning the ice maker, and an electrical circuit for circulating an electrical current. It is usually important to separate the three circuits in that, for example, water in any water circuit must not leak into the electrical circuit or into the foam insulation walls of the cooling circuit, hot air must not leak into areas where the chilled air and water promote ice formation, and electricity must not leak into the water (and vice versa). When assembling the ice maker to the ice storage container, even more complexities are introduced. In order to separate the various circuits while at the same time promoting harmonious interaction between them, it may be advantageous to consistently and tightly assemble the various subcomponents of the ice maker while separating them from one another, as appropriate.

[0004] The care required to build an ice maker that can withstand the difficult environments in which it often operates can add significant cost and complexity to the ice maker and its use. By way of example only, the use of additional materials and fasteners to join or assemble parts of the ice maker can require significantly more labor and require specialized skills. Additionally, ice maker cleaning procedures that do not take these same factors into account may require manual intervention by the user, potentially taking the user away from other duties. Summary of the Invention [Means for solving the problem]

[0005] It should be understood that this summary is not an exhaustive summary of the disclosure. The summary is illustrative and not limiting, and is not intended to identify key or critical elements of the disclosure or to delineate the scope thereof. The sole purpose of the summary is to describe and illustrate certain concepts of the disclosure as a prelude to the full and exhaustive detailed description that follows.

[0006] Disclosed is an ice maker including an evaporator case including a dry section and a wet section adjacent the dry section and sized to receive an evaporator, the evaporator case including a plurality of inner panels joined together by snap-fit ​​joints, each of the snap-fit ​​joints including a tab and defining a slot, each of a plurality of seams formed between the inner panels defining a foam-tight and watertight seal, and a plurality of outer panels, each of the plurality of outer panels joined to a counterpart of the plurality of inner panels by a sliding joint, the evaporator case being defined by the plurality of outer panels and the plurality of inner panels and being integrally insulated by blown foam insulation disposed within an insulation cavity defined between the plurality of outer panels and the plurality of inner panels.

[0007] Also disclosed is a method of manufacturing an ice maker, the method including: assembling a plurality of inner panels of an evaporator case together with snap fit joints by inserting a tab of each snap fit joint into a corresponding slot of the snap fit joint; forming a foam tight and water tight seal at a seam defined by the connection between the inner panels; assembling a plurality of outer panels to the inner panels with slide joints by inserting a lip of each slide joint into a corresponding groove of the slide joint, the grooves being defined at least in part by one of a plurality of tapered protrusions defined in each inner panel; and insulating the evaporator case with blown foam insulation disposed within an insulation cavity defined by and between the plurality of outer panels and the plurality of inner panels.

[0008] Also disclosed is a method of using an ice maker including forming ice on an evaporator of the ice maker, the evaporator being housed in an evaporator case of the ice maker; recovering ice from the evaporator; cleaning the evaporator, the cleaning of the evaporator including activating a switch of the ice maker in a first manual intervention of the overall cleaning procedure to initiate an overall cleaning procedure, sounding an audible alarm to notify a user that a second manual intervention is required, pouring a cleaning fluid into a tank of the evaporator case in the second manual intervention, automatically initiating and completing one of a cleaning phase and a sanitizing phase upon completion of the second manual intervention, the automatically initiating one of the cleaning phase and the sanitizing phase including operating a cleaning valve of a water circuit of the ice maker by a main controller of the ice maker, and automatically initiating and completing a rinsing phase.

[0009] Various implementations described in this disclosure may include additional systems, methods, features, and advantages not necessarily specifically disclosed herein, but which will become apparent to those skilled in the art upon consideration of the following detailed description and the accompanying drawings. All such systems, methods, features, and advantages are intended to be included within this disclosure and protected by the appended claims. The features and advantages of such implementations may be realized or obtained by means of the systems, methods, features particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and the appended claims, or may be learned by the practice of such exemplary implementations as set forth below.

[0010] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate several aspects of the present disclosure and, together with the description, serve to explain various principles of the present disclosure. The drawings are not necessarily drawn to scale. Corresponding features and components may be designated with corresponding reference characters throughout the figures for purposes of consistency and clarity. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 is a front perspective view of an ice making machine including an ice maker and a storage container according to one aspect of the present disclosure. [Figure 2A] FIG. 2 is a front perspective view of the ice maker of FIG. 1 with the outer casing of the ice maker removed. [Figure 2B] 2 is a front perspective view of the ice maker of FIG. 1 further showing the front and top insulation of the evaporator case of the ice maker and the base case cover of the compressor base of the ice maker removed; FIG. [Figure 2C] FIG. 2 is a front perspective exploded view of the spray tube, water pump, and other components of the water circuit of the ice maker of FIG. 1. [Diagram 3] FIG. 2 is a circuit diagram showing a cooling circuit and a water circuit of the ice cream maker of FIG. 1. [Figure 4] 2 is a perspective view of an exemplary ice cube produced by the ice maker of FIG. 1. [Figure 5A]FIG. 2C is a front perspective view of the evaporator case of FIG. 2B. [Figure 5B] 5B is a cross-sectional side view of the evaporator case of FIG. 2B taken along line 5B-5B shown in FIG. 5A. [Figure 6A] FIG. 5B is a perspective view of a float switch in the tank of the evaporator case of FIG. 5A. [Figure 6B] FIG. 6B is a perspective view of the float switch mount of FIG. 6A. [Figure 6C] FIG. 6B is a rear view of the float switch mount of FIG. 6A. [Figure 7] FIG. 5B is a detailed cross-sectional view of the evaporator case of FIG. 5A with the lip of the front insulation engaging the top insulation. [Figure 8] FIG. 5B is a detailed cross-sectional view of the evaporator case of FIG. 5A with the lip of the front insulation engaging the top end of the tank. [Figure 9] FIG. 5B is a detailed cross-sectional view of the evaporator case of FIG. 5A, in which the lip of the evaporator wall of the evaporator case engages the insulation rear edge of the top insulation. [Figure 10] FIG. 5B is a front perspective view of the evaporator case of FIG. 5A in a partially assembled state with the top insulation partially removed or disengaged. [Figure 11] FIG. 5B is a front perspective view of the evaporator case of FIG. 5A with the top insulation seated approximately in place between the evaporator walls and not yet secured to the evaporator walls. [Figure 12] FIG. 5B is a detailed front perspective view of the evaporator case of FIG. 5A with the top insulation fully seated. [Figure 13] FIG. 5B is a front top perspective view of the evaporator case of FIG. 5A with the front and top insulation removed. [Figure 14] 14 is a detailed front top perspective view of the tank of the evaporator case of FIG. 5A taken from detail 14 of FIG. 13. [Figure 15] FIG. 5B is a top perspective view of the evaporator case of FIG. 5A with the spray tube removed. [Figure 16] FIG. 5B is a front perspective view of the evaporator case of FIG. 5A with the spray tube, water pump, and thermal insulation tube of the ice maker removed. [Figure 17] FIG. 2D is a top view of the spray tube of FIG. 2C. [Figure 18] 18 is a detail front perspective view of the evaporator case of FIG. 5A taken from detail 18 of FIG. 13 showing the manifold end of the spray tube of FIG. 17. [Figure 19] FIG. 18 is a detailed bottom perspective view of the spray tube of FIG. 17 showing the manifold end and shown assembled with the supply tube of the water circuit. [Figure 20] FIG. 18 is a detailed bottom perspective view of the spray tube of FIG. 17 with the supply tube removed. [Figure 21] FIG. 18 is a side perspective view of the spray tube of FIG. [Figure 22] FIG. 5B is a detailed front perspective view of the evaporator case of FIG. 5A showing the top insulation, evaporator bracket, and evaporator wall. [Figure 23] FIG. 5B is a detailed front perspective view of the evaporator case of FIG. 5A showing the evaporator bracket partially removed or disengaged from the evaporator wall. [Figure 24] 24 is a detailed perspective view of the evaporator case of FIG. 5A showing the first pocket of the evaporator wall of FIG. 23. FIG. [Diagram 25] FIG. 23 is a bottom, upward perspective view of the evaporator bracket of FIG. 22. [Figure 26] FIG. 2 is a detailed front angled perspective view of the ice maker of FIG. 1 with the outer casing front panel assembly removed and prior to assembly of the evaporator case. [Figure 27] FIG. 27 is a detailed perspective view of the ice maker of FIG. 26, focusing on the upper end of the left side panel of the evaporator case. [Figure 28A] FIG. 5B is a perspective view of a second pocket in the evaporator wall of the evaporator case of FIG. 5A. [Figure 28B] 28B is a detailed cross-sectional view of the evaporator case of FIG. 5A taken from line 28B-28B of FIG. 28A, showing the panel upper end of the left side panel assembled to the evaporator wall of the evaporator case. [Figure 29A]FIG. 5B is a detailed perspective view of the evaporator case of FIG. 5A showing the bottom horizontal lip of the left side panel of the evaporator case and the groove defined by the tank base. [Figure 29B] 29B is a detailed cross-sectional view of the evaporator case of FIG. 5A taken from line 29B-29B of FIG. 29A, showing the panel bottom end of the left side panel assembled to the evaporator wall of the evaporator case. [Figure 29C] FIG. 2 is a detailed perspective view of a portion of the interior of a general embodiment of the insulated wall of the ice maker of FIG. 1. [Figure 29D] 5B is a cross-sectional perspective view of the evaporator section of the evaporator case of FIG. 5A, looking toward the back panel of the evaporator case. [Figure 29E] FIG. 1 is a top cross-sectional perspective view of the evaporator section looking towards the tank. [Diagram 30] FIG. 5B is a top view of the tank base of the evaporator case of FIG. 5A. [Diagram 31] 5B is a rear perspective view of the evaporator case of FIG. 5A and the liner of the compressor base of FIG. 2B, with the rear panel and inner side panels shown attached to the evaporator case. [Diagram 32] FIG. 5B is a front top exploded perspective view of the evaporator wall and tank of the evaporator case of FIG. 5A. [Diagram 33] FIG. 33 is a detailed front exploded perspective view of the lower wall end of the tank and evaporator wall taken from detail 33 of FIG. 32. [Diagram 34] FIG. 5B is a detailed exploded perspective view of the tank of the evaporator case and the lower end of the evaporator wall of FIG. 5A. [Diagram 35] FIG. 2 is a detailed perspective view of a lower wall end of the evaporator wall and an upper tank end of the tank, which are fixed to each other. [Figure 36A] FIG. 5B is a rear exploded perspective view of the evaporator wall and tank of the evaporator case of FIG. 5A during assembly. [Figure 36B] FIG. 37 is a rear perspective view of the evaporator wall and tank of FIG. 36 after assembly. [Figure 37A] FIG. 35 is a detailed cross-sectional view of the lip at the lower end of the evaporator wall engaged with a groove at the upper end of the tank of FIG. 34 at the location of the tab-slot combination. [Figure 37B]FIG. 37B is a detailed cross-sectional view of the structure shown in FIG. 37A at the location of the tab-slot combination. [Figure 38] 2 is a bottom perspective view of the lower end of the ice maker of FIG. 1. FIG. [Figure 39] FIG. 2 is a front view of the ice maker of FIG. 1. [Diagram 40] FIG. 2 is a front perspective view of the ice maker of FIG. 1 with the front panel assembly removed to expose the control box. [Diagram 41] 4 is an operational flowchart showing the overall operation of the controller of the ice maker of FIG. 1. [Diagram 42] 2 is a first cleaning flow chart showing a first stage in the process of either cleaning or sanitizing the ice maker of FIG. 1. [Diagram 43] 2 is a second cleaning flow chart showing a second stage in the process of either cleaning or sanitizing the ice maker of FIG. 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] The present disclosure can be more readily understood by reference to the following detailed description, examples, drawings, and claims, as well as the foregoing and following descriptions. However, before the present device, system, and / or method are disclosed and described, it should be understood that the present disclosure is not limited to the particular device, system, and / or method disclosed, unless otherwise indicated, and as such may, of course, vary. It should also be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.

[0013] The following description provides possible teachings of the device, system, and / or method in its best, currently known embodiment. To this end, those skilled in the art will recognize and appreciate that many changes can be made to the various aspects of the device, system, and / or method described herein while still obtaining the beneficial results of the present disclosure. It will also be apparent that some of the desired advantages of the present disclosure can be obtained by selecting some of the features of the present disclosure without using other features. Thus, those skilled in the art will recognize that many modifications and variations to the present disclosure are possible, and even may be desirable in certain circumstances, and are part of the present disclosure. Thus, the following description is provided as an illustration of the principles of the present disclosure, and not in limitation thereof.

[0014] As used throughout, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, a reference to "an element" may include two or more such elements unless the context dictates otherwise. In addition, any element described herein may be a first such element, a second such element, etc. (e.g., a first widget and a second widget, even if only a "widget" is referenced).

[0015] Ranges may be expressed herein as from "about" one particular value and / or to "about" another particular value. When such a range is expressed, another aspect includes from the one particular value and / or to the other particular value. Similarly, when values ​​are expressed as approximations, by use of the preposition "about" or "substantially," it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both relative to the other endpoint, and independently of the other endpoint.

[0016] For purposes of this disclosure, a material property or dimension that is about or substantially X on a particular measurement scale is within a range between X plus the industry standard upper tolerance of the particular measurement and X minus the industry standard lower tolerance of the particular measurement. Because tolerances can vary between different materials, processes, and different models, the tolerance of a particular measurement of a particular component can fall within various tolerance ranges.

[0017] As used herein, the term "optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes instances in which the event or circumstance occurs and instances in which the event or circumstance does not occur.

[0018] As used herein, the word "or" means any one member of a particular list and includes any combination of the members of that list. As used herein, the phrase "at least one of A and B" means "only A, only B, or both A and B," and the phrase "one of A and B" means "A or B."

[0019] Disclosed are components that can be used to implement the disclosed methods and systems. While these and other components are disclosed herein, and combinations, subsets, interactions, groups, etc. of these components are disclosed, it is understood that unless specific reference is made to each of the various individual and collective combinations and permutations thereof, each of all methods and systems is specifically contemplated and described herein. This applies to all aspects of this application, including but not limited to the steps of the disclosed methods. Thus, if there are various additional steps that can be implemented, it is understood that each of these additional steps can be implemented with any particular aspect or combination of aspects of the disclosed methods.

[0020] To simplify the description of the various elements disclosed herein, reference may be made to the conventions of "left", "right", "front", "rear", "top", "bottom", "upper", "lower", "inside", "outside", "inboard", "outboard", "horizontal" and / or "vertical". Unless otherwise specified, "front" refers to the end of the ice making machine closest to and occupied by a user of the ice making machine, "rear" refers to the opposite or distal end from the front, "left" refers to the left or left-facing side of a person standing in front of the ice making machine and facing toward the front, and "right" refers to the right or right-facing side of this same person. "Horizontal" or "horizontal orientation" refers to being in a plane extending from left to right and aligned with the horizon. "Vertical" or "vertical orientation" means lying in a plane that is at an angle of 90 degrees to the horizontal.

[0021] Disclosed is an ice making machine, as well as related methods, systems, devices, and various apparatus. The ice making machine may include an ice maker and a storage container. Those skilled in the art will appreciate that the disclosed ice making machine is described with only a few exemplary aspects of many. No particular terminology or description should be considered to limit the scope of the disclosure or any claims arising therefrom.

[0022] 1 is a front perspective view of an ice making machine 100 according to one embodiment of the present disclosure. Ice making machine 100 may include an ice maker 110 and a storage bin 190. Ice maker 110 may be configured to make ice, which may be fed downward by gravity into storage bin 190. Storage bin 190 may be insulated to maintain a low temperature within the storage bin compartment and to prevent the ice from melting. In some embodiments, storage bin 190 may be refrigerated, and in other embodiments, storage bin 190 may not be refrigerated.

[0023] The ice maker 110 may include an exterior casing 120, which may be configured to house the ice maker 110 and its internal components. As shown, the exterior casing may include a front panel assembly 122. The front panel assembly 122 may extend from the maker top end 112 to the maker bottom end 114 of the ice maker 110 and from the maker left side 116a to the maker right side 116b of the ice maker 110. The front panel assembly 122 may define an air inlet opening 180 and may include an air filter 124. The air inlet opening 180 and the air filter 124 may be configured to provide ventilation of the ice maker 110 in the form of clean air from outside the ice maker 110.

[0024] The storage container 190 may define a container upper end 192 onto which the maker lower end 114 of the ice maker 110 may be mounted. The storage container 190 may include a container door 194 located proximate the container upper end 192, which may provide access to a container storage compartment (not shown) defined within the storage container 190.

[0025] FIG. 2A is a front perspective view of the ice maker 110 of FIG. 1 with the outer casing 120 (shown in FIG. 1) removed. In this embodiment, the ice maker 110 may be an air-cooled model that may be cooled, for example, by circulating air within the outer casing 120 through the air inlet opening 180 (shown in FIG. 1). In some embodiments, the ice maker 110 may be a water-cooled model or may be coupled to a remote condensing unit for cooling. In this embodiment, the ice maker 110 may include a fan assembly 280 that may be configured to circulate air within the ice maker 110. The ice maker 110 and its body 200 may be compartmentalized into a wet section 202 and a dry section 204 under or within the outer casing 120 and may further include a frame 201 and a base case 205. The wet section 202 may be primarily defined by an evaporator case 206 that may be insulated. The evaporator case 206 may house most of the components of the water circuit 450 (shown in FIG. 3) of the ice maker 110, which may be configured to form ice from liquid water delivered to and circulated through the ice maker 110. The evaporator section 306 (shown in FIG. 2B) of the evaporator case 206 may be insulated. The evaporator case 206 may include, for example and without limitation, a removable front insulation 208 and a removable top insulation 210 that may partially house and insulate the evaporator section 306. Either the front insulation 208 or the top insulation 210 may be a panel or an insulating panel. In addition, as described further below, the tank 214 (which may be a water tank) and the evaporator walls 207a,b (207a shown in FIG. 2B) of the evaporator case 206 may be integrally insulated. By "integrally insulated" it is meant that the walls of the ice maker 110 may be filled with liquid foam insulation while the ice maker 110 or its insulation portion is supported in a foam molding jig or mold. Such insulation may be, for example, without limitation, a water or refrigerant foam high or low pressure foam that may flow through the walls of the ice maker 110, set, and harden causing the walls to develop insulating properties. The pressure of such foam may reach 14 psi or even greater than atmospheric pressure.Each of the tank 214, the evaporator walls 207a, b, and any other panels that form a portion of the interior of the evaporator case 206 or base case 205, such as, for example and without limitation, the molded inner panel of the compressor base 226 shown in FIG. 31, may be an inner panel.

[0026] The water circuit 450 may include a water pump 212 that may be mounted on or adjacent to the tank 214 at a location external to the evaporator section 306. The portion of the tank 214 that houses the water pump 212 may not be insulated. The tank 214 may be located below the evaporator walls 207a,b. The water pump 212 may be configured to pump water from the tank 214 upwardly into the evaporator section 306 where the water may be formed into ice.

[0027] The drying section 204 may house most of the components of the cooling circuit 400 (shown in FIG. 4) of the ice maker 110, including, for example, but not limited to, the compressor 220, the dryer 222, and the condenser 224. The compressor 220 may be mounted to a compressor base 226, which may include a horizontal compressor base panel to which the compressor may be more directly mounted. The compressor base 226 may include a base case cover 228. Within the drying section 204, the refrigerant flowing through the cooling circuit 400 may be compressed by the compressor 220 and then cooled to a liquid state in the condenser 224 before being delivered through an expansion device 240 (shown in FIG. 3), such as a thermostatic expansion valve, to the evaporator 310 housed within the evaporator section 306. Additionally, the control box 230 of the ice maker 110, which may include a controller 232, may be housed within the drying section 204. The controller 232 may be a control panel.

[0028] The ultrasonic container sensor 290 may be installed in the drying section 204 and may extend into the compressor base 226. The ultrasonic container sensor 290 may be configured to monitor the level of ice cubes 490 (shown in FIG. 4) accumulated in the storage container 190 (shown in FIG. 1). The ultrasonic container sensor 290 may function as a proximity sensor by transmitting ultrasonic waves downward toward the ice and receiving ultrasonic waves reflected from the ice cubes 490. The distance from a level position defined by the outlet of the ultrasonic container sensor 290 to a level position defined by the level of the ice cubes 490 may be determined from the travel time of the return ultrasonic waves. The ultrasonic container sensor 290 may be in electronic communication with the control box 230. When the level of the ice cubes 490 in the storage container 190 reaches a stop height, which may be a desired and predetermined value set by a technician or user of the ice maker 110, a signal from the ultrasonic container sensor 290 may be received by the control box 230, which may stop the ice making process, thereby stopping further production of ice cubes 490. As ice melts or is removed from the storage bin 190, the level may reach the refill height. When the level of ice cubes 490 in the storage bin 190 reaches the refill height, the ultrasonic bin sensor 290 may send a signal to the control box 230 which may restart the ice making process to refill the storage bin 190 with ice cubes 490. The "full" height or level may be a desired and predetermined value set by a technician or user of the ice maker 110 or the "full" height may be programmed into the controller 232.

[0029] 2B is a front perspective view of the ice maker 110 of FIG. 2 with the front insulation 208 and top insulation 210 of the evaporator case 206 and the base case cover 228 of the compressor base 226 further removed. By removing the front insulation 208 and top insulation 210, the evaporator section 306 can be exposed. The evaporator 310 and the spray tube 312 can be housed within the evaporator section 306 between the evaporator wall 207a and the evaporator wall 207b. The spray tube 312 can be disposed adjacent to the top end of the evaporator case 206 and above the evaporator 310 and coupled to the evaporator 310.

[0030] The cooling circuit 400 may include an evaporator 310 in which liquid refrigerant may be evaporated into a gas phase to cool the evaporator section 306 below the freezing temperature of water. Liquid water may be pumped by a water pump 212 to a spray tube 312 where it may be sprayed towards the evaporator 310 to form ice. A suction hose 560 may couple the water pump 212 to a tank 214 to provide a source of water for making ice. The body 200, and specifically at least the base case 205, may define a bottom opening 3814 at the maker bottom end 114 of the ice maker 110.

[0031] 2C shows a front perspective exploded view of the spray tube 312, the water pump 212, and other components of the water circuit 450. The water circuit 450 may include one or more valves 350, each of which may be a solenoid valve operated by the controller 232. More specifically, the water circuit 450 may include an inlet water valve 352, a cleaning valve 354, and a drain valve 356. The water circuit 450 may include a supply tube 1930, which may be coupled to the inlet water valve 352 and the cleaning valve 354 by a supply tube inlet pipe 362. Meanwhile, the inlet water valve 352 may be in fluid communication with water entering the ice maker 110 at a water inlet 372 and through an inlet water valve inlet pipe 364. The water circuit 450 may include a drain pipe or drain hose 366, which may be coupled to the drain valve 356 by a drain valve outlet pipe 368 and may allow water to be drained from the ice maker 110 at a water outlet 374. The water circuit 450 may include a float switch 690 .

[0032] FIG. 3 is a circuit diagram illustrating the interactions and interconnections between the various components of the cooling circuit 400 and the water circuit 450 of the ice maker 110 of FIG.

[0033] 4 illustrates a perspective view of ice cubes 490 in one exemplary embodiment. In some embodiments, ice cubes 490 can define, at least in part, a crescent shape, as shown. In some embodiments, ice cubes 490 can define a non-crescent shape. Ice cubes 490 can define a height H, a width W, and a depth D. In some embodiments, height H can be about 1.5 inches (about 38.1 millimeters), width W can be about 1.125 inches (about 28.6 mm), and depth D can be about 0.5 inches (about 12.7 mm). In other embodiments, ice cubes 490 can be smaller or larger in any dimension and can have various shapes such that ice cubes 490 are not identical.

[0034] FIG. 5A is a front perspective view of the evaporator case 206 of FIG. 2. As shown, the evaporator wall 207b can define a cooling port 506 that can be defined in and extend through the evaporator wall 207b to the evaporator compartment 306. The cooling port 506 can provide access for the lines of the cooling circuit 400 (shown in FIG. 3) to reach the evaporator 310 (shown in FIG. 2B). The evaporator wall 207b can define a wall upper end 507b and a wall lower end 508b disposed opposite the wall upper end 507b. The tank 214 can define a tank upper end 514 and a tank lower end 515 disposed opposite the tank upper end 514. As shown, and as further described below with respect to FIGS. 32-37B, the tank upper end 514 can be attached to the wall lower end 508b by a snap or snap-fit ​​connection. The top insulation 210 can rest on the wall top edge 507b, and the top insulation 210 can slide horizontally inward and outward from between the evaporator wall 207a and the evaporator wall 207b (207a is shown in FIG. 2B).

[0035] The tank 214 may define a tank exterior 530a and a tank interior 530b disposed opposite the tank exterior 530a. The tank interior 530b may be substantially aligned with the evaporator wall 207b. The tank 214 may include a removable ice cube guide 550 disposed proximate the tank top 514 or may be at least partially covered or surrounded by the removable ice cube guide 550. The ice cube guide 550 may slope downwardly from the tank exterior 530a to the tank interior 530b. The ice cube guide 550 may lead to an ice cube opening 552 defined by the tank interior 530b. The ice cube guide 550 may be slid into the tank 214 by sliding the ice cube guide 550 into the ice cube opening 552 until the ice cube guide 550 is set behind or below a lip 553 of the ice cube opening 552. To remove the ice cube guide 550, the ice cube guide 550 can be lifted over the lip 553 and slid outward from the tank 214 through the ice cube opening 552. The ice cube guide 550 can define holes 551 that can facilitate removal of the ice cube guide 550. For example, a user can slide a finger into the holes 551 to assist in lifting the ice cube guide 550 over the lip 553.

[0036] The ice cube guide 550 may be configured to guide the ice cubes 490 that exit the evaporator case 206 downward under gravity and exit the ice cube opening 552. The ice cubes 490 that exit through the ice cube opening 552 may be discharged through the bottom opening 3814 (shown in FIG. 38) below the compressor base 226 (shown in FIG. 2A). The ice maker 110 (shown in FIG. 1) may be positioned above the storage vessel 190 (shown in FIG. 1) such that the opening (not shown) of the storage vessel 190 may be aligned below the compressor base 226 and with the bottom opening 3814. The ice cubes 490 that fall from the ice cube opening 552 may fall below the compressor base 226 and through the bottom opening 3814 and into the opening of the storage vessel 190 to fill the storage vessel 190.

[0037] A water reservoir 614 (shown in FIG. 5B) can be defined below the ice cube guide 550 and between the tank exterior 530a and tank interior 530b. A suction hose 560 can be in fluid communication with the water reservoir 614 through the tank interior 530b and in fluid communication with the water pump 212 to supply water to the water pump 212. Thus, the water pump 212 can discharge water upward through the tank top 514, through the insulated pipe 512 and into the evaporator section 306.

[0038] The evaporator wall 207b can define a front end 509b and a rear end 510b disposed opposite the front end 509b. The front insulation 208 can be disposed at the front end 509b between the evaporator wall 207a and the evaporator wall 207b. The front insulation 208 can define an insulation upper end 520 and an insulation lower end 521 disposed opposite the insulation upper end 520. The insulation upper end 520 can define a lip 620 (shown in FIG. 5B) that can engage the top insulation 210, and the insulation lower end 521 can define a lip 621 (shown in FIG. 5B) that can engage the tank upper end 514 to secure the front insulation 208 to the evaporator case 206. To remove the front insulation 208, the top insulation 210 can be removed, so that the insulation top end 520 can be rotated away from the front end 509b while the insulation bottom end 521 is pivoted about the tank top end 514 until the front insulation 208 is released. The front insulation 208 can define a pull tab 522 configured to provide a gripping surface for rotating the insulation top end 520 away from the front end 509b. Advancement of the pull tab 522 with the top insulation 210 fully installed can cause the lip 620 to capture and push the top insulation 210, thereby facilitating removal of the top insulation 210. The engagement between the front insulation 208, the tank top end 514, and the top insulation 210, including the lips 620, 621, is further shown in FIG. 5B.

[0039] FIG. 5B is a cross-sectional side view of the evaporator case 206 of FIG. 2B taken along line 5B-5B shown in FIG. 5A. This cross-sectional plane may substantially bisect the insulation tube 512. The top insulation 210 may define an insulation front end 610 and an insulation rear end 612 disposed opposite the insulation front end 610. The insulation rear end 612 may be vertically captured by a lip 613 defined by the wall upper end 507a of the evaporator wall 207a and the wall upper end 507b of the evaporator wall 207b (shown in FIG. 5A). The evaporator wall 207a may further define a front end 509a, a rear end 510a, and a wall lower end 508a, which may correspond to the front end 509b, a rear end 510b, and a wall lower end 508b (shown in FIG. 5A, respectively) of the evaporator wall 207b. As shown, and as described below with respect to Figures 10-12, the insulation front end 610 may be secured to the evaporator walls 207a,b.

[0040] The insulated tubes 512 can carry water from the water pump 212 to the spray tubes 312. The spray tubes 312 can extend from a front end 509a to an aft end 510a, and the spray tubes 312 can be configured to spray water from various points along their length downward into a series of channels 640 defined by the evaporator plates 650 of the evaporator 310. The evaporator 310 can further include tubes 652 that can weave forward and backward between the evaporator plates 650 in a serpentine path to facilitate heat exchange between the tubes 652 and adjacent, opposing evaporator plates 650. As the liquid refrigerant flowing through the evaporator 310 begins to evaporate to a gaseous state, the refrigerant can absorb heat from the water sprayed by the spray tubes 312 against the outside of the evaporator plates 650, thereby forming ice cubes 490 (shown in FIG. 4 ) within the channels 640. Once the ice cubes 490 are large enough, which may be determined by the passage of a predetermined ice making interval during an ice formation cycle, the ice cubes 490 may be removed from the evaporator by initiating a recovery cycle. While the evaporator 310 is heating during the recovery cycle, the ice cubes 490 may fall downward and be redirected by the ice cube guide 550. The ice cube guide 550 may define an opening such that the ice cubes 490 are redirected by the ice cube guide 550 toward the ice cube opening 552 while unfrozen liquid water dripping down the evaporator plate 650 may flow through the ice cube guide 550 back into the water reservoir 614.

[0041] A float switch 690 may be disposed in the water reservoir 614 of the tank 214. The float switch 690 may measure the level of water in the water reservoir 614. When the water level falls below a set minimum, the float switch 690 may send a signal to the controller 232 (shown in FIG. 2A ) to supply more water to the tank 214.

[0042] As shown, the evaporator case 206 may further include a tank base 602. The tank base 602 may define a split collar 604 that may be configured to receive and frictionally engage a post 606 defined by the tank 214. The friction engagement between the post 606 and the split collar 604 may facilitate assembly of the evaporator case 206 by providing a tool-less, push-together connection.

[0043] FIG. 6A is a perspective view of a float switch 690 in the tank 214. The float switch 690 may be mounted to a float switch mount 691. The float switch mount 691 may include a support arm 692 and a mounting bracket 694. The support arm 692 may define an opening 693 (shown in FIG. 6B) through which the float switch 690 may be secured, such as by a nut or other fastener. The mounting bracket 694 may define a mounting channel 695. The mounting channel 695 may receive a protrusion 696 defined by the tank 214. The tank 214 may be formed by an injection molding process, one advantage of which is the ability to integrally, i.e., seamlessly, form detailed features such as the protrusion 696, boss 1050 (shown in FIG. 10), and other features of the evaporator case 206 as described herein, rather than being attached as separate components. "Monolithic" means at least cast, molded, or formed as a single piece. More specifically, each seamless component may be formed in a single operation from a single material without any welds or mechanical connections, such as threads, flanges, fasteners, interference fits, adhesives, brazing, soldering, or other mechanical connection methods, to at least join the features described as being seamless or formed seamless. The protrusion 696 may taper slightly upwardly, and the mounting channel 695 may define a complementary shape to securely fasten the float switch mount 691 to the protrusion 696.

[0044] 6B is a perspective view of a float switch mount 691 within the tank 214. As shown, a mounting bracket 694 can be positioned on the protrusion 696, and a mounting channel 695 can be aligned with the protrusion 696 such that the mounting bracket 694 can be installed on the protrusion 696 by lowering the mounting bracket 694 onto the protrusion 696. As shown, the protrusion can define a pocket 697, and the mounting bracket 694 can define a latching arm 698 configured to engage the pocket 697, thereby securing the mounting bracket 694 to the protrusion 696.

[0045] 6C is a rear view of the float switch mount 691 facing the mounting bracket 694. As shown, the latching arm 698 can at least partially define a mounting channel 695. The latching arm 698 can also define a positioning tab 699 that can extend into the mounting channel 695. The positioning tab 699 can be configured to engage a pocket 697 (shown in FIG. 6B) to horizontally and vertically secure and fix the position of the mounting bracket 694 over the protrusion 696 (shown in FIG. 6B).

[0046] FIG. 7 is a detailed cross-sectional view of the lip 620 of the front insulation 208 engaging the top insulation 210. The lip 620 of the front insulation 208 is shown interfering with the top insulation 210, but in its final assembled position the lip 620 may be located between the rows 730 of the top insulation 210. The top insulation 210 may include a top insulation liner 710 and a top insulation sheet 720. FIG. 8 is a detailed cross-sectional view of the lip 621 of the front insulation 208 engaging the tank top end 514 of the tank 214. FIG. 9 is a detailed cross-sectional view of the lip 613 of the evaporator wall 207a engaging the insulation rear end 612 of the top insulation 210.

[0047] 10-12 show the top insulation 210 slid into place between the evaporator walls 207a and 207b. In FIG. 10, the insulation trailing edge 612 of the top insulation 210 can be disposed between the evaporator walls 207a and 207b, and the insulation leading edge 610 can extend laterally outward from between the evaporator walls 207a and 207b. The top insulation 210 can define a pair of rails that can extend longitudinally along each side of the top insulation 210, as shown by rail 1010 on one side of the top insulation 210.

[0048] FIG. 11 shows the top insulation 210 seated approximately in place between the evaporator walls 207a and 207b, but not yet secured to the evaporator walls 207a,b. As shown by rails 1010, a pair of rails can rest along the wall top edges 507a,b (507a shown in FIG. 5B) of the evaporator walls 207a,b. As shown by evaporator wall 207b, the evaporator walls 207a,b can define cutouts 1107 located near the corners of the wall top edges 507a,b (507a shown in FIG. 5B) and the front edges 509a,b (the cutouts defined by the evaporator wall 207a are not shown). The cutouts 1107 can extend laterally inwardly from and through the thickness of the front edges 509a,b. The top insulation 210 can define tabs 1110 on either side of the insulation front end 610. In this illustration, the tabs 1110 can be aligned with but disengaged from the cutouts 1107.

[0049] 12 is a detailed front perspective view of the evaporator case 206 showing the top insulation 210 in an installed and secured configuration. As shown, the top insulation 210 can be fully positioned between the evaporator walls 207a and 207b, and the tabs 1110 can be inserted into the cutouts 1107, thereby securing the insulation front end 610 to the evaporator walls 207a,b.

[0050] FIG. 13 is a front top perspective view of the evaporator case 206 of FIG. 2A with the front insulation 208 and the top insulation 210 removed. Each evaporator wall 207a,b can be substantially L-shaped, with the rear end 510a and the rear end 510b connected together to form the back panel 1307 of the evaporator case 206. The evaporator case 206 can include a pair of evaporator brackets 1320a,b. The evaporator bracket 1320a can be positioned proximate the front end 509a,b, and the evaporator bracket 1320b can be positioned proximate the rear end 510a,b. The evaporator brackets 1320a,b can slide vertically downward between the evaporator wall 207a and the evaporator wall 207b to secure the evaporator brackets 1320a,b within the evaporator compartment 306.

[0051] The evaporator brackets 1320a,b can support the spray tube 312 and the evaporator 310. The spray tube 312 can define a manifold end 1310 disposed between the evaporator bracket 1320a and the front end 509a,b. The spray tube 312 can also define two tube portions 1312a,b that can split from the manifold end 1310 and extend between the evaporator bracket 1320a and the evaporator bracket 1320b. The manifold end 1310 can be connected to a thermally insulated pipe 512, and water pumped upward from the water pump 212 can be redirected through the manifold end 1310 to the tube portions 1312a,b. When the ice maker 110 is making ice, the tube portions 1312a,b can spray water downward into the evaporator 310. In contrast, the supply tube 1930 (shown in FIG. 2C) can spray water into the evaporator 310 (including parts of the evaporator 310 that do not receive water from the spray tube 312) as the ice maker 110 cleans itself during a cleaning or sanitizing cycle described below.

[0052] FIG. 14 is a detailed front top perspective view of the tank 214 of the evaporator case 206. The tank top end 514 may define a sloped spout 1414. The spout 1414 may slope downward from a front end of the tank 214 located proximate the front ends 509a,b of the evaporator walls 207a,b toward the ice cube guide 550. As described in more detail below, during cleaning of the ice maker 110 (shown in FIG. 1), a water reservoir 614 (shown in FIG. 5B) in the tank 214 may be drained and refilled with cleaning solution. The spout 1414 may assist in filling the water reservoir with cleaning solution. The cleaning solution may be poured onto the spout 1414 and directed downward along the spout 1414 and through the ice cube guide 550 to fill the water reservoir 614. The cleaning solution may then be circulated by the water pump 212 into the water circuit 450 (shown in FIG. 3).

[0053] 15 is a top perspective view of the evaporator case 206 with the spray tubes 312 removed. As shown, the evaporator 310 may include four evaporator plates 650 that may be paired into two evaporator plate assemblies 1550a,b. The evaporator plate assemblies 1550a,b may extend between the evaporator bracket 1320a and the evaporator bracket 1320b to secure the evaporator 310 within the evaporator section 306. Two tube circuits 1552a,b may extend between adjacent evaporator plates 650 of each evaporator plate assembly 1550a,b. The tube circuits 1552a,b may each be configured in a serpentine pattern extending rearward and forward between the evaporator bracket 1320a and the evaporator bracket 1320b. The tube circuits 1552a,b and the evaporator plates 650 may each include a thermally conductive material such as copper, stainless steel, aluminum, brass, or any other suitable material. For example, without limitation, the tube circuits 1552a,b can include copper tubing and the evaporator plate 650 can include stainless steel. Each evaporator plate assembly 1550a,b can operate as a heat exchanger. More specifically, heat from the evaporator plate 650 can be absorbed by evaporating the refrigerant circulating within the tube circuits 1552a,b to cool the evaporator 310 below the freezing point of water.

[0054] Each evaporator plate 650 can define a plurality of channels 640. In operation, the two tube portions 1312a,b (shown in FIG. 13) of the spray tube 312 (shown in FIG. 13) can be aligned with the two evaporator plate assemblies 1550a,b of the evaporator plate 650, respectively. The tube portions 1312a,b can each define a plurality of spray nozzles 1910 (shown in FIG. 19) that can be aligned with the plurality of channels 640 defined by the evaporator plate 650 on each side of each evaporator plate assembly 1550a,b, respectively. The spray nozzles 1910 can spray water along the channels 640 that can individually form ice cubes 490.

[0055] FIG. 16 is a front perspective view of the evaporator case 206 with the spray tube 312, the water pump 212, and the thermal insulation tube 512 removed. As shown, each evaporator plate assembly 1550a,b of the evaporator plate 650 can be secured to the evaporator brackets 1320a,b (1320b shown in FIG. 15) by a plurality of fasteners 1650 as shown by the evaporator bracket 1320a. In addition, the tube circuits 1552a,b can be connected in fluid communication by a crossover tube 1652 to form a single-loop cooling circuit 400 (shown in FIG. 4). In addition, as shown by the evaporator bracket 1320a, each one of the evaporator brackets 1320a,b can define a pair of tube openings 1612a,b. Each tube opening 1612a,b can be configured to receive and support a different one of the tube portions 1312a,b (shown in FIG. 13) of the spray tube 312 (shown in FIG. 13).

[0056] By removing the water pump 212 from the pumping compartment 1660 of the tank 214, a drain port 1662 of the pumping compartment 1660 can be exposed. The drain port 1662 leads to the tank base 602 (shown in FIG. 6 ) and allows any water that may collect within the pumping compartment 1660 to drain from the pumping compartment 1660 and outside the ice maker 110.

[0057] 17 is a top view of the spray tube 312 of FIG. 3. The spray tube 312 can include a pair of lever arms 1712a,b, each of which can be attached to a different one of the opposing tube sections 1312a,b. The lever arms 1712a,b can be resilient and flexible, and the lever arms 1712a,b can be biased to extend outwardly from each tube section 1312a,b toward the manifold end 1310. Each lever arm 1712a,b can define an engagement notch 1714a,b and an end 1716a,b, respectively. The spray tube 312 can also include a pair of caps 1710a,b, which can seal the tube sections 1312a,b opposite the manifold end 1310.

[0058] FIG. 18 is a detailed front perspective view of the evaporator case 206 focusing on the manifold end 1310 of the spray tube 312 of FIG. 3. As previously described, each tube section 1312a,b can extend through a different one of the tube openings 1612a,b, and the evaporator bracket 1310a can support the manifold end 1310 of the spray tube 312. The lever arms 1712a,b can also extend through the tube openings 1612a,b with each attached tube section 1312a,b. The engagement notches 1714a,b can each engage an edge of a different one of the tube openings 1612a,b, thereby laterally securing the spray tube 312 to the evaporator bracket 1310a and preventing the tube sections 1312a,b from disengaging from the tube openings 1612a,b. The lever arms 1712a,b can be disengaged from the tube openings 1612a,b by pushing the ends 1716a,b inward toward the manifold end 1310. Once the lever arms 1712a,b are disengaged from the tube openings 1612a,b, the spray tube 312 can be pulled laterally outward from the evaporator bracket 1310a, such as to facilitate cleaning or maintenance of the spray tube 312.

[0059] FIG. 19 is a detailed bottom perspective view of the spray tube 312 of FIG. 3, focusing on the manifold end 1310. As shown, each tube portion 1312a,b can define a plurality of spray nozzles 1910. The spray nozzles 1910 can be configured to align with the channels 640 (shown in FIG. 15) defined by the evaporator plate 650 (shown in FIG. 15). A pair of spray guides 1912a,b can be disposed below the spray tube 312. The spray guides 1912a,b can each extend along a bottom surface of the tube portions 1312a,b. Each spray guide 1912a,b can define a plurality of channel guides 1914 that can align with different ones of the spray nozzles 1910. The channel guides 1914 can each be configured to align with a different one of the channels 640 to guide liquid water along each channel 640.

[0060] As better shown below in FIG. 20, each tube portion 1312a,b can define two rows of spray nozzles 1910, and each spray guide 1912a,b can define two rows 1916a-d of channel guides 1914, respectively. In addition, a supply tube 1930 can be disposed below the spray tube 312. The supply tube 1930 can define a supply manifold end 1940 having a connection 1942. The supply tube 1930 can also include a pair of supply tube portions 1932a,b. Each supply tube portion 1932a,b can extend along one of the tube portions 1312a,b between adjacent rows 1916a-d of the channel guide 1914. For example, the supply tube portion 1932a can extend along the tube portion 1312a between adjacent rows 1916a and 1916b of the channel guide 1914. The supply tube portions 1932a,b can each define a plurality of supply nozzles 1934 that can spray cleaning fluid, sanitizing fluid, and water between the evaporator plates 650 (shown in FIG. 15) of the evaporator plate assemblies 1550a,b (shown in FIG. 15) during cleaning and sanitizing of the ice maker to respectively clean, sanitize, and rinse areas of the evaporator 310 that would be difficult to clean.

[0061] FIG. 20 is a detailed bottom perspective view of the spray tube 312 of FIG. 19, showing without the supply tube 1930 and the spray guides 1912a,b. As previously mentioned, the spray nozzles 1910 may be arranged in two rows 2012a-d along each tube portion 1312a,b, respectively. For example, two rows 2012a,b of spray nozzles 1910 may extend along the tube portion 1312a. In addition, two rows 2016a-d of guide tabs 2014 may extend along each tube portion 1312a,b, with the guide tabs 2014 spaced apart between the spray nozzles 1910. The guide tabs 2014 may assist in aligning the spray guides 1912a,b (shown in FIG. 19) with the spray nozzles 1910.

[0062] FIG. 21 is a side perspective view of the spray tube 312 of FIG. 19, without the feed tube 1930 and spray guides 1912a,b. As is typically done in the prior art, the spray tube 312 can be integrally or seamlessly formed from a single piece using methods such as blow molding. Alternatively, the spray tube 312 can include a top panel 2112 and a bottom panel 2114. The top panel 2112 and the bottom panel 2114 can be separately formed pieces, such as, for example, without limitation, by injection molding. The top panel 2112 and the bottom panel 2114 can be attached to one another at a seam 2116, such as, for example, without limitation, by techniques such as vibration welding. Vibration welding is a rapid and chemical-free technique that can weld parts together. The top panel 2112 and the bottom panel 2114 can be rubbed together under pressure with a vibrating forming tool to create friction that can weld the parent materials of the panels 2112, 2114. The weld is then allowed to cool.

[0063] In this embodiment, the caps 1710a,b can also be removed from each tube portion 1312a,b to reveal the end openings 2110a,b. In contrast to blow molded spray tubes that typically have small rough-edged holes defining each end opening 2110a,b, the end openings 2110a,b of the spray tube 312 formed from the panels 2112, 2114 can be wide open slots configured to allow easy access for cleaning, such as with a brush or high pressure spray stream. In this embodiment, the caps 1710a,b can be configured to fit securely over the end openings 2110a,b without tools to facilitate assembly and maintenance.

[0064] 22 is a detailed front view of the top insulation 210, evaporator bracket 1310a, and evaporator walls 207a,b of the evaporator case 206. As shown, the evaporator bracket 1310a can define an upper flange 2210. The upper flange 2210 can define a pair of vanes 2212a,b on either side of the upper flange 2210. The evaporator walls 207a,b can each define an inner shelf 2207a,b, and the top insulation 210 can rest on the inner shelves 2207a,b. As shown by the evaporator wall 207a, the inner shelf 2207a can be defined below the wall upper end 507a. The evaporator bracket 1310a (evaporator bracket 1310b is shown in FIG. 13) may be configured to be lifted vertically upward to remove the evaporator bracket 1310a,b from between the evaporator walls 207a and 207b. With the top insulation 210 in place, the evaporator bracket 1310a,b may be blocked such that it cannot be lifted vertically.

[0065] 23 is a detailed front perspective view of the evaporator bracket 1310a and evaporator walls 207a,b of the evaporator case 206 with the evaporator bracket 1310a partially removed from the evaporator walls 207a,b. By lifting the evaporator bracket 1310a vertically upward, the vanes 2212a,b can be disengaged from a pair of watertight pockets 2307a,b that extend into and are defined on the inner shelves 2207a,b of the evaporator walls 207a,b, respectively. In contrast to the case where the evaporator walls 207a,b are formed using a vacuum forming method, as is typically done in the past, the pockets 2307a,b can be formed without exposing any blown foam or other insulating material present behind the evaporator walls 207a,b.

[0066] 24 is a detailed perspective view of the pocket 2307a in the evaporator wall 207a. As shown, the pocket 2307a can define a groove 2402 extending longitudinally along the inner shelf 2207a and a vertical cutout 2404 extending inwardly from the groove 2402 into the evaporator section 306. In this embodiment, the evaporator walls 207a,b (207b shown in FIG. 23) can be formed by injection molding and the pocket 2307a can be integrally formed within the evaporator wall 207a. As suggested above, in this embodiment, the pocket 2307a does not extend into the evaporator wall 207a, thereby providing watertight protection of the foam insulation from the pocket 2307a.

[0067] Figure 25 is a bottom, upward perspective view of the evaporator bracket 1310a of Figure 13. As shown, the vanes 2212a can define longitudinal tabs 2502 that can be configured to engage the grooves 2402 (shown in Figure 24) and vertical ridges 2504 that are configured to engage the vertical cutouts 2404 (shown in Figure 24).

[0068] As mentioned above, the evaporator walls 207a,b have traditionally been formed using vacuum forming methods from polymeric materials such as acrylonitrile butadiene styrene (ABS). However, vacuum formed parts can and necessarily vary in thickness to varying degrees throughout the part, and may vary in dimensions from part to part more significantly than parts formed using injection molding methods due to varying shrinkage in different manufacturing conditions. After formation of the individual vacuum formed parts, the parts are typically joined using a solvent welding method. During solvent welding, a mixture of a solvent such as acetone, or a monomer mixture including a solvent such as acetone, and the ground (i.e., reduced to small pieces) raw material (e.g., ground ABS) from which the parts are formed can be used, for example, but not limited to, to soften the material of the panels 2112, 2114, and the panels 2112, 2114 can be pressed together until the material hardens and hardens again. Although the monomers used during solvent welding can solidify within minutes, a 24 hour cure time is typically required, and the quality of solvent welded joints can vary widely depending on the skill of the operator assembling components such as the evaporator walls 207a,b and tank 214. Additionally, solvent welding often involves chemicals that can produce unpleasant fumes during use.

[0069] In contrast, and as described above, the tank 214 of the evaporator case 206 as well as the evaporator walls 207a,b can be individually formed from a material such as ABS or any other desired and moldable material using a molding method such as injection molding. As described, the parts of the evaporator case 206 can then be very tightly joined together without any fasteners or even any solvent welding method to form an evaporator case 206 that is watertight and resistant to leakage of blown foam through the joints (i.e., foam-tight) during the manufacturing process, particularly during the process of forming the evaporator case 206. Water foam insulation can have a particularly low viscosity, so that it can remain in a water-like state for as long as 10 seconds or more after being sprayed on an insulation assembly such as the evaporator case 206, making the watertight and foam-tight joints even more beneficial not only against water intrusion during the operation of the ice maker 110, but also against water leakage from the seams of the insulation assembly such as the evaporator case 206 during the foam molding process.

[0070] 26 is a detailed front angled perspective view of the ice maker 110 of FIG. 1 with the front panel assembly 122 (shown in FIG. 1) of the outer casing 120 removed, prior to assembly of the evaporator case 206. As shown, the left side panel 2620 of the outer casing 120 is offset outwardly from the evaporator wall 207a of the evaporator case 206, and the top panel assembly 2622 of the outer casing 120 is offset above the top insulation 210. The left side panel and any other panels forming a portion of the exterior of the evaporator case 206 or base case 205 may be exterior panels.

[0071] FIG. 27 is a detailed perspective view of a portion of the ice maker 110 shown in FIG. 26, focusing on the panel top edge 2720 of the left side panel 2620. The left side panel 2620 can define a vertical portion 2722, a lip 2724 (which may be a top lip) disposed at the panel top edge 2720, and a lip 2734 (which may be a side lip) disposed at the front panel edge 2732. The lip 2724 can extend inwardly toward the evaporator case 206. The evaporator wall 207a can define a groove 2707 that extends from the front end 209a to the rear end 210a. The groove 2707 can be defined below the wall top edge 507a. Within the groove 2707, the evaporator wall 207a can define a plurality of upwardly sloping protrusions 2709 that extend into the groove 2707 and can be sloped protrusions. The upwardly angled protrusion 2709 can slope upwardly and inwardly into the groove 2707. As shown, the upwardly angled protrusion 2709 and the groove bottom wall 2790, which can extend between the upwardly angled protrusion 2709, can extend the same distance toward the left side panel 2620 and contact and form a seal against the left side panel 2620 during foam molding of the assembly.

[0072] In some embodiments, the groove 2707 can be oriented horizontally and the lip 2724 can be oriented horizontally, as shown and described. In other embodiments, the groove 2707 can be oriented vertically and the lip 2724 can be oriented vertically, for example and without limitation, proximate the front ends 509a,b (shown in FIG. 11 ) of the evaporator walls 207a,b (207b shown in FIG. 11 ). The groove 2707 can thus be a horizontal or vertical groove in any portion of the evaporator case 206, and the lip 2724 can be a horizontal or vertical lip in any panel. Similarly, other portions of the evaporator case can define a groove 2707 that can be oriented horizontally, vertically, or any other desired orientation between the horizontal and vertical orientations.

[0073] The groove 2707 can be configured to receive a lip 2724 to attach the left side panel 2620 to the evaporator wall 207a. The lip 2724 can be inserted into the groove 2707. The lip 2724 can slide over the upwardly angled protrusion 2709 to a fully seated position, thereby forming a sliding joint. Additionally, the left side panel 2620 can define a pair of tabs 2730. In this embodiment, the tabs 2730 can be cut out of the lip 2724 and plastically bent at an angle upward and away from the lip 2724. As shown below in FIG. 28, each of the tabs 2730 can engage a watertight pocket 2830 defined in the groove 2707. Each of the tabs 2730 can be a lance tab that can resiliently deform during assembly at least with, if not toward, a peripheral portion of the lip 2724 to allow for insertion of the lip 2724. The tab 2730, with or without a peripheral portion of the lip 2724, can then resiliently deform to its original position and engage in or with the pocket 2830.

[0074] 28A is a perspective view of a pocket 2830 in the evaporator wall 207a of FIG. 2. The pocket 2830 may be defined by an upper surface of a groove 2707 facing an upwardly angled protrusion 2709. The upwardly angled protrusion 2709 may push a lip 2724 (shown in FIG. 27) and a tab 2730 (shown in FIG. 27) upward and into engagement with the pocket 2830 to secure the panel top edge 2720 of the left side panel 2620 to the evaporator wall 207a. This attachment mechanism may provide a simple snap-fit ​​assembly that does not require any tools.

[0075] FIG. 28B shows a detailed cross-sectional view of the panel top end 2720 of the left side panel 2620 assembled to the evaporator wall 207a of the evaporator case 206 at the sliding joint described above. A groove 2707 can be defined between the groove top wall 2760 and the groove bottom wall 2790. As shown, the groove bottom wall 2790 can extend outwardly from the evaporator wall 207a and contact the vertical portion 2722 of the left side panel 2620, which can serve as a standoff between the evaporator wall 207a and the left side panel 2620, similar to the standing rib 2984 (shown in FIG. 29B) described below, which defines the flat portion of the standing rib 2884. An insulation cavity 2792 can be defined below the groove bottom wall 2790 and between the vertical portion 2722 of the left side panel 2620 and the evaporator wall 207a. An overflow insulation cavity 2794 may be defined above the groove bottom wall 2790, below the lip 2724, and between the vertical portion 2722 of the left side panel 2620 and the evaporator wall 207a.

[0076] The tab 2730 can be formed by shearing a portion of the lip 2724 and bending a small portion into the lip 2724 such that a water-tight and foam-tight closed lance is formed. As shown, the shearing and bending of the lip 2724 to form the tab 130 can stop short of the entire thickness of the material of the lip 2724. Even if an open lance is used, the opening in the tab 2730 can be sized such that excess foam that reaches the overflow insulation cavity 2794 does not easily pass through the opening.

[0077] As previously described, liquid foam can be sprayed or injected into the insulation cavity 2792, and the liquid foam can expand and harden as it hardens. Under pressure, the insulation cavity 2792 can be completely filled with liquid foam to completely insulate the evaporator case 206 (shown in FIG. 2). It can be difficult to fill the insulation cavity 2792 accurately without slightly underfilling it, leaving voids in the insulation, or slightly overfilling it, in which case excess insulation may leak out of the insulation cavity 2792. The overflow insulation cavity 2794 can provide a space into which the overfilled foam can slowly leak in and expand (but only inside the walls, as described below), without compromising the aesthetics of the ice making machine 100 (shown in FIG. 1), such as by exposing the foam insulation that has gone through the exterior casing 120 (shown in FIG. 1). For example, the insulation cavity 2792 may be purposely overfilled under pressure to prevent voids in the insulation, if desired, or the blowing agent, such as, for example, but not limited to, the water-blown foam described above, may have a low viscosity and still not easily leak out of the assembly during foam molding. The excess foam may leak partially between the vertical portion 2722 and the channel bottom wall 2790, and the insulation may expand and harden in the overflow insulation cavity 2794. The left side panel 2620 may hide the overflow insulation cavity 2794 so that the user cannot see the leaked foam in the overflow insulation cavity 2794. The improvements described herein may also reduce or eliminate the amount of time required for typical assembly processes (e.g., taping joints, caulking seams, and / or applying putty at corners), and construction (e.g., tape, caulk, and putty), and post-foam molding to prepare the foamed portion of the ice maker 110 for foam molding before foam molding or to clean up leaked foam.

[0078] Such movement of excess foam into the overflow insulation cavity 2794 may be limited by the resistance to foam leakage into the overflow insulation cavity 2794 provided by a narrow gap 2708 specifically defined between the lip 2724 and the upwardly angled protrusion 2709. The gap 2708 may be represented as an entrance to the overflow insulation cavity 2794. Resistance to foam leakage into the overflow insulation cavity 2794 may also be provided by a seal between the interior surface 2623 of the left side panel 2620 and each of the groove bottom wall 2790 and the upwardly angled protrusion 2709 along the width of the left side panel 2620. Excess foam may only move within the gap 2708 under pressure from the walls of the foam molding jig sufficient to hold the left side panel 2620 against the groove bottom wall 2790 and each of the upwardly angled protrusions 2709. Furthermore, the offset 2870 between the outer surface 2621 of the left side panel 2620 and the adjacent outer surface of the evaporator wall 207a, and also the offset 2890 between the end of the lip 2724 of the left side panel 2620 and the evaporator wall 207a in the insertion direction of the lip 2724, can ensure uniform pressure between the left side panel 2620 and each of the groove bottom wall 2790 and the upwardly inclined protrusion 2709, even if there is variation due to manufacturing tolerances, for example, in the width of the lip 2724 or any dimension of other parts, and the variation can be absorbed by the offset 2890 or the offset 2870.

[0079] The upwardly angled projections 2709 position the lip 2724 in close proximity to the groove top wall 2760 to prevent expanding insulation entering the overflow insulation cavity 2794 from leaking out between the lip 2724 of the left side panel 2620 and the groove top wall 2760 of the evaporator wall 207a. Additionally, the interface between the lip 2724 and the interior sealing lip 2780 can provide additional protection to prevent foam from leaking out between the lip 2724 and the groove top wall 2760. The interior sealing lip 2780 can extend between adjacent upwardly angled projections 2709, and the lip 2724 can be at least partially positioned between the interior sealing lip 2780 and the groove top wall 2760. These features may eliminate the need for an assembler to tape, seal, or putty the seam between the left side panel 2620 and the evaporator wall 207a (a measure that may not be effective in preventing low viscosity water-blown foams from leaking through the seam defined between the left side panel 2620 and the evaporator wall 207a, but may be at least partially effective with some blown foams). Eliminating the need to tape, seal, or putty the seam may save a great deal of time during assembly and foam molding of the insulation cavity 2794.

[0080] 29A is a detailed perspective view of the bottom lip 2920 of the left side panel 2620 and the groove 2907 defined by the tank base 602. Similar to the groove 2707 (shown in FIG. 27), the tank base 602 can define a plurality of downwardly sloping protrusions 2909 that slope downwardly and inwardly into the groove 2907 and can be sloped protrusions. The downwardly sloping protrusions 2909 can guide the bottom lip 2920 into a fully seated position within the groove 2907. Additionally, the bottom lip 2920 can define a tab 2730 that can engage a watertight pocket 3030 (shown in FIG. 30) similar to the pocket 2830 (shown in FIG. 28A) shown facing the groove 2907. As shown, the downwardly inclined protrusion 2909 and the groove upper wall 2990 which may extend between the downwardly inclined protrusion 2909 extend the same distance toward the left side panel 2620 and can contact and form a seal against the left side panel 2620 during foam molding of the assembly.

[0081] 5B , the tank base 602 can define a split collar 604 that can be configured to receive and frictionally engage the post 606 defined by the tank 214. The split collar 604 can define a split portion 2904, and the split collar 604 can be configured to resiliently flex radially outwardly to receive and frictionally engage the post 606.

[0082] FIG. 29B shows a detailed cross-sectional view of the panel bottom end of the left side panel 2620 assembled to the tank base 602 at another of the slide joints. As with the embodiment of FIG. 28B, in this embodiment an overflow insulation cavity 2994 can be defined between the left side panel 2620 and the tank base 602. A groove 2907 can be defined between a groove top wall 2990 and a groove bottom wall 2960. As shown, the groove top wall 2990 can extend outwardly from the tank base 602 and contact the vertical portion 2722 of the left side panel 2620. An insulation cavity 2792 can be defined above the groove top wall 2990 and inwardly from the vertical portion 2722 of the left side panel 2620. An overflow insulation cavity 2994 may be defined below the groove top wall 2990, above the bottom lip 2920, and between the vertical portion 2722 of the left side panel 2620 and the tank base 602. The overflow insulation cavity 2994 (located behind the downwardly sloping protrusion 2909 in FIG. 29B) may be configured to allow for controlled overflow of excess foam insulation sprayed into the insulation cavity 2994 similar to the insulation cavity 2792 (shown in FIG. 28B). The tab 2730 is shown engaged with the pocket 3030.

[0083] The downwardly angled projection 2909 may position the bottom lip 2920 in close proximity to the groove bottom wall 2960 to prevent the expanding insulation from leaking out between the bottom lip 2920 of the left side panel 2620 and the groove bottom wall 2960 of the tank base 602. The interior sealing lip 2980 may provide additional protection to prevent the foam from leaking out between the bottom lip 2920 and the groove bottom wall 2960, similar to the interior sealing lip 2780 of FIG. 27B. As with other portions of the evaporator case 206, including the structure shown in FIG. 28B, migration of excess foam into the overflow insulation cavity 2994 may be limited by the resistance to foam leakage into the overflow insulation cavity 2994 provided by the narrow gap 2908 specifically defined between the lip 2920 and the downwardly angled projection 2909. The gap 2908 may represent an entrance to the overflow insulation cavity 2994. Resistance to foam leakage into the overflow insulation cavity 2794 may also be provided by seals along the width of the left side panel 2620 between the interior surface 2623 of the left side panel 2620 and the channel top wall 2990 and downwardly angled protrusions 2909, respectively. Excess foam may only migrate within the gap 2908 under pressure from the walls of the foam molding jig sufficient to hold the left side panel 2620 against the channel top wall 2990 and downwardly angled protrusions 2909, respectively. Furthermore, the offset 2970 between the outer surface 2621 of the left side panel 2620 and the adjacent outer surface of the evaporator wall 207a, and also the offset 2990 between the end of the bottom lip 2920 of the left side panel 2620 and the evaporator wall 207a in the insertion direction of the lip 2920, can ensure uniform pressure between the left side panel 2620 and each of the groove upper wall 2990 and the downwardly inclined protrusion 2909, even if there is variation due to manufacturing tolerances, for example, in the width of the lip 2920 or any dimension of other parts, and the variation can be absorbed by the offset 2990 or the offset 2970.

[0084] 29C is a detailed perspective view of a general embodiment of one corner of the evaporator walls 207a,b, or any other portion of the evaporator walls 207a,b, showing the interior sealing lip 2982, the interior standing ribs 2884, 2984, and the exterior rib 2986. The interior sealing lip 2982 may be configured to function similarly to the interior sealing lip 2780 and the interior sealing lip 2980. The interior standing ribs 2884, 2984 may be configured to function similarly to the groove bottom wall 2790 and the groove top wall 2990. The exterior rib 2986 may be configured to function similarly to the groove top wall 2760 and the groove bottom wall 2960. The gaps 2708, 2908 between the interior standing ribs 2884, 2984 (and in particular the angled protrusions 2709, 2909 at the ends of the interior standing ribs 2984) and the exterior panel (e.g., the left side panel 2620 shown in FIG. 29A, which is removed in FIG. 29C but offset from each end of the interior standing ribs 2884, 2984 when assembled to the evaporator wall 207a) can limit foam flow from the insulation cavity 2792 into the overflow insulation cavity 2794, 2994, as described above. Additionally, at the corners of the interior panels, such as the evaporator wall 207a, the structure described above can prevent foam from leaking through gaps formed at the intersections between the lips, such as where the bottom end of the lip 2734 (shown in FIG. 27) meets the front end of the bottom lip 2920 (shown in FIG. 29B). As shown, the dividing line 2900 can be adjusted and positioned as needed on various inner or outer panels throughout the joint of the ice maker 110, dividing feature 2900a and feature 2900b, only example portions of which are explicitly shown.

[0085] FIG. 29D is a cross-sectional perspective view of the evaporator section 306 looking toward the back panel 1307 of the evaporator case 206. As shown, the insulation cavity 2792 can extend around the evaporator walls 207a,b and the tank 214. A first portion 2999a of the insulation cavity 2792 can be defined between the evaporator wall 207a and the left side panel 2620. A second portion 2999b of the insulation cavity 2792 can be defined between the tank 214 and the tank base 602. A third portion 2999c of the insulation cavity 2792 can be defined between the evaporator wall 207b and the interior side panel 2930. The right side panel or the interior side panel 2930 can be attached to the evaporator wall 207b in a manner similar to the attachment of the left side panel 2620 to the evaporator wall 207a as described with respect to FIGS. 26-29B. Each of the sections 2999a-c can be connected in fluid communication and completely filled with foam insulation in one foam molding operation.

[0086] 29E is a top cross-sectional perspective view of the evaporator section 306 looking toward the tank 214. As shown, a fourth portion 2999d of the insulation cavity 2792 can be defined between the back panel 1307 and the rear panel 3120 of the outer casing 120. The rear panel 3120 can extend between the interior side panel 2930 and the left side panel 2620 and can house the insulation cavity 2792. The fourth portion 2999d can join the first portion 2999a to the third portion 2999c.

[0087] 30 is a top view of the tank base 602 of FIG. 6. The split collar 604 can define a plurality of radial projections 3004 therein. Each radial projection 3004 can define a horizontal shelf that can support the post 606 (shown in FIG. 29) in all three dimensions (X, Y, and Z) when the post 606 is inserted into the split collar 604. A sufficiently wide stance or diameter of the split collar 604 can support and maintain the position of the tank 214 during the foam molding process under significant mechanical and foam pressures that may occur while the evaporator case 206 and other portions of the ice maker 110 are in the foam molding jig. Forming the multiple radial protrusions 3004 in a vertical orientation not only facilitates the manufacturing, particularly molding, of the tank base 602, but also allows the openings shown in the split collar 604 to allow foam to flow into the split collar 604 to ensure insulation throughout the area between the tank base 602 and the tank 214.

[0088] As discussed above, the tank base 602 can define a pocket 3030. The tank base 602 can additionally define a pocket 3030 near the rear end 3014 of the base 602, which can be configured to receive the rear panel 3120 (shown in FIG. 31 ) by an attachment mechanism similar to that described above for the left side panel 2620 (shown in FIG. 26 ) in the description of FIGS. 26-29 . Any sheet metal or similar thin panels of the evaporator case 206 can be similarly attached to any evaporator wall of the evaporator case 206, as desired.

[0089] The tank base 602 can also define an exhaust channel 3010 and a drain port 3012 that leads to an aft end 3014 of the tank base 602. The exhaust channel 3010 can be configured to collect water from a drain port 1662 (shown in FIG. 16) of a pumping section 1660 (shown in FIG. 16), in which the water pump 212 (shown in FIG. 2) can be located.

[0090] FIG. 31 is a rear perspective view of the evaporator case 206 and the liner of the compressor base 226, with the rear panel 3120 and the interior side panel 2930 shown attached to the evaporator case 206. The rear panel 3120 and the interior side panel 2930 can be attached to the evaporator case 206 as similarly described for the left side panel 2620 (shown in FIG. 26) in the description of FIGS. 26-29. As shown, a pair of bosses 3106 of the evaporator wall 207b can extend into the interior side panel 2930. As shown, the compressor base 226 can define a plurality of downwardly angled protrusions 3109 similar to the downwardly angled protrusions 2909, which can slope downwardly and inwardly. The downwardly angled protrusions 2909 can be configured to frictionally engage the right side panel (not shown) of the outer casing 120 (shown in FIG. 1).

[0091] A plurality of outer panels, such as the left side panel 2620 (shown in FIG. 28B), and a plurality of inner panels, such as the evaporator wall 207a (shown in FIG. 28B), together can define a plurality of overflow insulation cavities 2794, 2994 (2794 shown in FIG. 28B and 2994 shown in FIG. 29B). The upstanding ribs 2884, 2984 (shown in FIG. 28B) and wall bodies 2850, 2950 (2850 shown in FIG. 28B and 2950 shown in FIG. 29B) of the inner panels, and the exterior surface 2621 (shown in FIG. 28B) can define a plurality of overflow insulation cavities 2794, 2994, respectively. In each overflow insulation cavity 2794, 2994, the exterior surface 2621 of the outer panel may contact the standing rib 2884, 2984 of the inner panel 261 to define a seal therebetween. The flow of blown foam insulation from the insulation cavity 2792 to each overflow insulation cavity 2794, 2994 may be restricted by blocking the overflow insulation cavity 2794, 2994 from the insulation cavity 2792, except for a pair of gaps 2708, 2908. A first gap 2708 of the pair of gaps 2708, 2908 may be defined at least in part by a first sloped protrusion 2709, 2909 at a first end of the standing rib 2884, 2984. A second gap 2908 of the pair of gaps 2708, 2908 may be defined at least in part by a second sloped protrusion 2709, 2909 at a second end of the standing rib 2884, 2984. A cross-sectional area of ​​the overflow insulation cavity 2794, 2994 in each of the first gap 2709 and second gap 2909 may be smaller than a cross-sectional area of ​​the overflow insulation cavity 2794, 2994 at a position offset from the first gap 2708 and second gap 2908, respectively.

[0092] 32 is a front top exploded perspective view of the evaporator walls 207a,b and the tank 214 of FIG. 2, respectively. The tank 214 can define an overflow drain 3214 disposed within the water reservoir 614. The tank 214 can further define a drain passage 3216 in fluid communication with the overflow drain 3214, which can lead to a drain channel 3010 (shown in FIG. 30) in the tank base 602 (shown in FIG. 6). To prevent overflow of the tank 214, the overflow drain 3214 can be configured to drain water from the water reservoir 614 when the water level rises above an upper end of the overflow drain 3214.

[0093] 33 is a detailed front top exploded perspective view of the tank 214 and the wall lower ends 508a,b of the evaporator walls 207a,b, respectively. The tank upper end 514 can define a pair of grooves 3314a,b that can be configured to receive the wall lower ends 508a,b of each of the evaporator walls 207a,b, respectively, for attaching the tank 214 to the evaporator walls 207a,b. Each of the grooves 3314a,b can define one or more slots 3320 that can extend into the respective grooves 3314a,b.

[0094] FIG. 34 is a detailed exploded perspective view of the tank 214 and the wall lower end 508a of the evaporator wall 207a. The wall lower end 508a can define a lip 3414 that can be configured to be received within a groove 3314a (shown in FIG. 33) of the tank upper end 514. The lip 3414 can define a tab 3420 that can be configured to engage with a slot 3320 defined by the tank 214, with a barb as shown. The evaporator wall 207b (shown in FIG. 33) can define a similar lip and tab configured to engage with a groove 3314b (shown in FIG. 33) and a slot 3320 (shown in FIG. 33) defined within the groove 3314b.

[0095] FIG. 35 is a detailed perspective view of the wall lower end 508a of the evaporator wall 207a and the tank upper end 514 of the tank 214 secured together. In this embodiment, the lip 3414 (shown in FIG. 34) can be received within the groove 3314a (shown in FIG. 33). The lip 3414 can be received within the groove 3314a to allow the tab 3420 to engage the slot 3320, thereby securing the evaporator wall 207a to the tank 214. The evaporator wall 207b (shown in FIG. 33) can similarly be attached to the tank 214. The engagement of the tab 3420 and the slot 3320 can provide a snap-together, tool-free assembly that can save time during the assembly process.

[0096] FIG. 36A is a rear exploded perspective view of the evaporator walls 207a,b and tank 214 of FIG. 2A. As described above with respect to FIG. 13, each evaporator wall 207a,b can be substantially L-shaped with rear ends 510a,b connected together at a rear seam to form the back panel 1307 (shown in FIG. 36B) of the evaporator case 206 (shown in FIG. 36B). Similar to the grooves 3314a,b (shown in FIG. 33), the evaporator wall 207a can define a slot 3622 that can be similar to the slot 3320 (shown in FIG. 33). The evaporator wall 207b can define a lip 3614 that is similar to the lip 3414 (shown in FIG. 34) that can define a tab 3620 that is similar to the tab 3420 (shown in FIG. 34). As shown, the groove 3314a can extend around the rear end of the tank top 514, and the groove 3314a can be configured to receive the wall bottom ends 508a,b.

[0097] Figure 36B is a perspective rear view of the back panel 1307 of the evaporator case 206 attached to the tank 214. A groove (not shown) in the evaporator wall 207a can receive the lip 3614 (shown in Figure 36A) of the evaporator wall 207b.

[0098] FIG. 37A shows the lip 3414 of the evaporator wall 207a received in a groove 3314a defined in the tank 214, and FIG. 37B shows the tab 3420 of the lip 3414 engaged with the slot 3320 of the groove 3314a (shown in FIG. 37A). As shown in FIG. 36B, the tab 3620 can similarly engage with a slot 3622 to secure the rear ends 510a,b together to form the back panel 1307 of the evaporator case 206. When assembled, the evaporator case 206 can seat on the tank top end 514 of the tank 214 as described above, and the tank 214 can be attached to the evaporator case 206. As desired, any two thicker portions of the evaporator case 206, such as, for example and without limitation, any portion of the evaporator walls 207a,b of the evaporator case 206, or more generally, the ice maker 110, can be similarly constructed and joined.

[0099] FIG. 38 is a bottom perspective view of the maker bottom end 114 of the ice maker 110 of FIG. 1. As shown, the tank base 602 and the base case 205 together can define the maker bottom end 114 and a bottom opening 3814. The bottom opening 3814 can be aligned with an opening (not shown) in the container top end 192 (shown in FIG. 1) of the storage container 190 (shown in FIG. 1). Ice cubes 490 made by the ice maker 110 can drop through the bottom opening 3814 into the storage container 190. The ultrasonic container sensor 290 can extend into the compressor base 226 and be positioned above the bottom opening 3814. As previously described, the ultrasonic container sensor 290 can transmit ultrasonic waves downward through the bottom opening 3814 into the storage container 190 to measure the level of the ice cubes 490 in the storage container 190.

[0100] 39 is a front view of the ice maker 110 of FIG. The front panel assembly 122 may be held onto the ice maker 110 by fasteners 3910, such as screws, located near the maker bottom end 114. Once the fasteners 3910 are loosened, the front panel assembly 122 may be lifted and removed from the ice maker 110 to provide access for maintenance, cleaning, or any other purpose. As described elsewhere herein and shown in the figures, removing one fastener 3910 may facilitate tool-less access for a user to the interior of the evaporator case, including the spout 1414, from the front of the ice maker.

[0101] FIG. 40 is a perspective view of the ice maker 110 with the front panel assembly 122 removed to expose the control box 230, the front insulation 208, and the tank 214. By pulling the pull tab 522 on the front insulation 208, the interior portion of the wet compartment 202 (shown in FIG. 2A) can be accessed for cleaning or the like. The control box 230 can include a first switch 4010 and a second switch 4012, both of which can be hidden behind the front panel assembly 122 to discourage tampering by unauthorized persons. Either of the switches 4010, 4012 can be a toggle switch. The first switch 4010 can be a control switch 4010 and the second switch 4012 can be a mode switch 4012.

[0102] To clean and sanitize the ice maker 110, the front panel assembly 122 (shown in FIG. 39) can first be removed as illustrated. Unless otherwise indicated, this step and any of the following manual steps can be performed by a user or technician of the ice making machine 100. The control switch can then be switched to the "off" position for three minutes while the mode switch 4012 is in the "ice" position. The control switch 4010 can then be moved to the "on" position and the front panel assembly 122 can be replaced. After three minutes, the front panel assembly 122 can again be removed and the control switch 4010 can be switched to the "off" position. The storage bin 190 (shown in FIG. 1) can then be emptied of ice and, if appropriate, turned off in preparation for cleaning.

[0103] The mode switch 4012 may then be switched to the "cleaning" position, after which the control switch 4010 may be moved to the "on" position. At this point, an automatic confirmation of the control switch 4010 being switched to the "on" position may occur by one short beep three seconds followed by one long beep. The front panel assembly 122 may then be replaced. During this time, the water reservoir 614 (shown in FIG. 6) of the tank 214 may be automatically drained and filled by the ice maker 110. The controller 232 of the control box 230 may then issue a beep (which may be in the form of a two-beep sequence, i.e., beep, beep, pause, then repeat), at which time the front panel assembly 122 may be removed and the control switch 4010 may be switched to the "off" position. The front insulation 208 can be removed and then a quantity of cleaning fluid, such as, for example, but not limited to, 10.4 fl. oz. of Hoshizaki SCALE AWAY cleaning fluid, can be poured into the water reservoir 614 through the spout 1414 (shown in FIG. 14). In some embodiments, the cleaning fluid can include 5.4 ounces of detergent per gallon. The control switch 4010 can then be switched to the "on" position, at which point the automatic confirmation can again occur by one short beep followed by one long beep three seconds after the one described above, and the front panel assembly 122 can be replaced. At this point, the mixture of cleaning fluid and water ("cleaning solution") can be recirculated in the water circuit 450 (shown in FIG. 4). A one minute delay can be automatically initiated before each cycle to avoid excessive foaming of the cleaning solution. After automatically circulating the cleaning solution in the water circuit 450 for 30 minutes, the ice maker 110 can automatically perform three rinse cycles in succession. Once the controller 232 begins beeping again (which may be in the form of a five beep sequence), the front panel assembly 122 can be removed and the control switch 4010 can be switched to the "off" position.In applications where the ice maker 110 is exposed to poor or harsh water conditions, the ice maker 110 can be powered off and the ice cube guide 550 (shown in FIG. 5), float switch 690 (shown in FIG. 6), water inlet tube, spray tube 312 (shown in FIG. 3), and spray guides 1912a,b (shown in FIG. 19) can be removed, cleaned, rinsed, and reinstalled. For example, and without limitation, the components can be cleaned in a solution of warm water to which Hoshizaki SCALE AWAY cleaning fluid can be added at a ratio of 5 oz. of cleaning solution to 1 gallon of warm water.

[0104] To sanitize the ice maker 110, the mode switch 4012 can be placed in the "cleaning" position, and then the control switch 4010 can be moved to the "on" position, where the automatic confirmation can again be performed by one short beep followed by one long beep three seconds after the one described above. The front panel assembly 122 can then be replaced. During this time, the water reservoir 614 of the tank 214 can be automatically drained and refilled. When the control box 230 begins to beep (which can be in the form of a two-beep sequence described above), the front panel assembly 122 can be removed and the control switch 4010 can be moved to the "off" position. The front insulation 208 can then be removed, and then a sanitizing fluid, such as, but not limited to, 0.6 fl. oz. of 8.25% sodium hypochlorite solution (chlorine bleach), can be added through the spout 1414 into the water reservoir 614 of the tank 214. In some embodiments, the sanitizing fluid may include a 200 parts per million solution of sodium hypochlorite based on the tank size and the concentration of active ingredients in the solution. The front insulation 208 may be replaced and the control switch 4010 may be moved to the "on" position, whereupon the automatic confirmation may again occur by one short beep followed by one long beep three seconds after the one described above. The front panel assembly 122 of the ice maker 110 may then be replaced. There may be an automatic one minute delay between cycles to avoid excessive foaming. After automatically circulating the sanitizing solution in the water circuit 450 for approximately 30 minutes, the ice maker 110 may then automatically perform three rinse cycles in succession. When the controller 232 begins to beep (which may again be in the form of the five beep sequence described above), the front panel assembly 122 may be removed and the control switch 4010 may be moved to the "off" position. The ice storage bin 190 may then be cleaned with a mild detergent and thoroughly rinsed. The mode switch 4012 can then be switched back to the "ice" position and the control switch 4010 can then be switched back to the "on" position to resume ice production.The front panel assembly 122 can then be reinstalled on the ice maker 110.

[0105] 41 to 43 show flow charts illustrating the operation of the controller 232 of the control box 230 with respect to at least the cleaning and sanitizing functions of the overall cleaning procedure of the ice maker. The full cycle through each flow chart described below may represent either a cleaning cycle or a sanitizing cycle. As shown in FIG. 41, the overall operational flow chart 4100 may include steps 4110 and 4120 related to cleaning and sanitizing. Step 4110 may include the controller 232 determining whether the mode switch 4012 is in the "cleaning" position. If the answer is no, then step 4120 may include the controller 232 determining whether the cleaning step is a rinse. Additionally, if the answer is no, then the cleaning cycle is not initiated by the controller 232. If the answer is yes to either step 4110 or step 4120, then the cleaning cycle is initiated beginning with the steps shown in the first cleaning flow chart 4200 (shown in FIG. 42).

[0106] As shown in FIG. 42, the first cleaning flowchart 4200 may include steps 4210-4290. Step 4210 may include the controller 232 turning off all relays in the control box 230. Step 4220 may include determining whether the mode switch 4012 is (still) in the cleaning position. If the answer is no, any subsequent steps of the first cleaning flowchart 4200 may be skipped and the controller 232 may jump to the steps of the second cleaning flowchart 4300. If the answer is yes, step 4230 may include sounding the buzzer for one second. Step 4240 may include the controller 232 determining whether the cleaning process is to begin. If the answer is no, again, any subsequent steps of the first cleaning flowchart 4200 may be skipped and the controller 232 may jump to the steps of the second cleaning flowchart 4300. If the answer is yes, step 4250 may include circulating water in the water circuit 450, as exemplarily described in the flowchart or above. More specifically, step 4250 may include turning on the cleaning valve 354 (shown in FIG. 3 ) and turning off the inlet water valve 352 (shown in FIG. 3 ) and the drain valve 356 (shown in FIG. 3 ). Step 4260 may include draining the water reservoir 614, as exemplarily described in the flowchart or above. More specifically, step 4260 may include turning on the drain valve 356 and turning off the inlet water valve 352 and the cleaning valve 354. Step 4270 may include filling the water reservoir 614, as exemplarily described in the flowchart or above. More specifically, step 4270 may include turning on the inlet water valve 352 and turning off the cleaning valve 354 and the drain valve 356. Step 4280 may include the controller 232 setting the cleaning step to the solution. Step 4290 may include the controller 232 sounding two short beeps every five seconds as a cue for the user to proceed to the next step (pouring cleaning fluid (if a cleaning cycle) or pouring disinfecting fluid (if a disinfecting cycle)).Indeed, any subset or all of steps 4220-4290 can be automated such that no user intervention is required, up to and including a cue for the user to pour the cleaning or sanitizing fluid. The first cleaning flowchart 4200 can then transition to the second cleaning flowchart 4300.

[0107] As shown in FIG. 43, a second cleaning flow chart 4300 may include steps 4310-4390 that may follow a user's injection of a cleaning fluid. Step 4310 may include the controller 232 determining if the cleaning step is a solution. If the answer is yes, step 4320 may include the controller 232 starting a one minute delay timer. Step 4330 may include the controller 232 setting the cleaning step to a rinse. Step 4340 may include the controller 232 circulating the cleaning solution through the water circuit 450 for a period of time, such as 30 minutes. During the last three minutes of the 30 minute period, or any other desired portion of a similar circulation period, the controller 232 may pulse the water pump, effectively using a rapid pressure tap to help more aggressively clean the surfaces of the water circuit 450 by removing limescale, calcium deposits, and other contaminants from the surfaces of the water circuit. Step 4350 may include the controller 232 draining the water reservoir 614. If the answer to step 4310 is no, the controller 232 may jump directly to steps 4340 and 4350 (i.e., the controller 232 may skip the rinse step). Steps 4360-4380 may include one rinse cycle. More specifically, step 4360 may include the controller 232 causing the water circuit 450 to fill the water reservoir 614, step 4370 may include the controller 232 causing the water pump to circulate water in the water circuit 450, and step 4380 may include the controller 232 causing the water pump to drain the water reservoir 614. Step 4390 may include the controller 232 repeating steps 4360-4380 until the third rinse cycle is completed. Step 4392 may include the controller 232 resetting the cleaning process to beginning (to prepare for the next full cleaning cycle in the future). Step 4394 may include the controller 232 sounding five long beeps every 10 seconds to inform the user that the cleaning cycle is complete.Additionally, any subset or all of steps 4310-4394 may be automated such that no user intervention is required. The above-described steps of the first cleaning flowchart 4200 and the second cleaning flowchart 4300 may be repeated to perform a disinfection cycle.

[0108] The process of cleaning and sanitizing the ice maker 110 can be useful for maintaining the quality (e.g., size, hardness, and clarity) of the ice cubes 490 and can also be useful for removing bacteria, such as Pseudomonas aeruginosa, from the system. Internal and regulatory agency (such as the National Sanitation Foundation, or NSF) testing has found that the process described herein can not only meet regulatory requirements for sanitation, but can also maintain a desired pH level of the water in the water circuit 450 after cleaning and sanitizing, which can be, for example, a pH value of 7 plus or minus 0.5.

[0109] Several advantages can be realized in the cleaning and disinfecting process described herein. Although some manual intervention by the user may be required in some embodiments, as already indicated, many steps that were manually timed and / or initiated in the conventionally implemented process are now automated. In the cleaning phase, for example, nine basic steps are reduced to five steps, with all timing steps built into the controller 232 (as evidenced by the various beeping cues to the user). In the disinfecting phase, the cleaning phase is followed by 14 basic steps, with similar five steps, with all timing steps built into the controller 232 (as evidenced by the various beeping cues to the user). In the conventionally implemented process, the water pump hose must be disconnected and reconnected multiple times during each phase, and the cleaning valve must also be opened and closed multiple times during each phase, making constant monitoring of the overall cleaning and disinfecting process possible for several hours, whereas in the method described herein, the user can walk away and return when prompted by the beeps on the control panel, eliminating the need for constant monitoring even for a two-hour cleaning process. The complexity of the water circuit 450 is also significantly reduced. What was previously required over 50 parts now requires only about 22 parts, a parts reduction of over 50%. This is possible by replacing the manual cleaning valves of the prior implementation with valves 352, 354, 356 as shown in FIG. 2C and controlling valves 352, 354, 356 with controller 232.

[0110] In particular, conditional language such as "can, could," "might," or "may" is intended to generally convey that certain aspects include certain features, elements, and / or steps, while other aspects do not, unless otherwise specified or understood within the context in which it is used. Thus, such conditional language does not generally imply that features, elements, and / or steps are in any way required by one or more particular aspects, or that one or more particular aspects necessarily include logic for determining, with or without user input or prompting, whether or not those features, elements, and / or steps are included in or performed in any particular aspect.

[0111] It should be emphasized that the above-described aspects are merely implementation examples merely described for a clear understanding of the principles of the present disclosure. As will be understood by those skilled in the art of the present disclosure, any process description or block in the flow chart should be understood to represent a module, segment, or code including one or more executable instructions for implementing a particular logical function or step in the process, including alternative implementations in which functions may not be included or may not be executed at all, and may be executed out of the order shown or described, including substantially simultaneously or in reverse order depending on the functionality involved. Many changes and modifications may be made to the above-described aspects without substantially departing from the spirit and principles of the present disclosure. Moreover, the scope of the present disclosure is intended to encompass all combinations and subcombinations of all elements, features, and aspects described above. All such modifications and variations are included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are supported by the present disclosure.

Claims

1. A drying section; a wet section adjacent to the dry section, the wet compartment includes an evaporator case sized to receive an evaporator; The evaporator case is a plurality of inner panels joined together by snap fit joints, each of the snap fit joints including a tab and defining a slot, each of a plurality of seams formed between the inner panels defining a foam tight seal and a water tight seal; a plurality of outer panels, each of the plurality of outer panels being joined to a corresponding one of the plurality of inner panels by a sliding joint; the evaporator case being integrally insulated by foam insulation disposed within an insulation cavity defined by a plurality of said outer panels and a plurality of said inner panels.

2. each of the plurality of inner panels includes one of a plurality of downwardly sloping first projections and a plurality of upwardly sloping second projections extending from a body of the respective inner panel, each of the first projections and the second projections at least partially defining a groove; 2. The ice maker of claim 1, wherein each of the plurality of outer panels includes a lip received within the groove of each of the inner panels, the lip defining a tab that engages with a watertight pocket defined in a surface of each of the inner panels.

3. The inner panels of the evaporator case include: a first evaporator wall; a second evaporator wall joined to the first evaporator wall by a first set of snap fit joints at a rear seam of the evaporator case; a tank joined to the first evaporator wall by a second set of snap fit joints and joined to the second evaporator wall by a third set of snap fit joints; 2. The ice maker of claim 1, wherein each of the snap fit joints of the first set of snap fit joints, the second set of snap fit joints, and the third set of snap fit joints includes a tab and defines a slot in a respective mating part of the first evaporator wall, the second evaporator wall, and the tank.

4. 4. The ice maker of claim 3, wherein each of said first evaporator wall, said second evaporator wall and said tank are integrally formed.

5. 4. The ice maker of claim 3, wherein each of the tabs of the snap fit joint defines a barb that is engaged with a corresponding slot of the snap fit joint.

6. the tank defines a spout that slopes downwardly from a forward end of the tank relative to a horizontal orientation; the spout is disposed adjacent to and between a front end of the first evaporator wall and a front end of the second evaporator wall; The ice maker of claim 3 , wherein the spout is configured to direct a cleaning solution into a water reservoir defined by the tank during a cleaning operation of the ice maker.

7. the evaporator case includes a tank for storing water used for making ice by the ice maker; the tank includes a third projection extending vertically from the tank and integrally formed with the tank; The ice maker comprises: a float switch mounting base facing both sides of the third protruding portion and fixed to the third protruding portion; 2. The ice maker of claim 1, further comprising a float switch secured to the float switch mount and configured to sense a level of the water in the tank.

8. a spray tube disposed adjacent to an upper end of the evaporator case and above the evaporator and coupled to the evaporator; The spray tube is an upper half and a lower half permanently and sealably joined to the upper half; the upper and lower halves defining an opening extending across more than half of the horizontal width of a tube portion of the spray tube; The ice maker of claim 1 , wherein the spray tube is configured to spray water onto the evaporator to make ice.

9. an evaporator bracket that fixes the evaporator to an upper end of the evaporator case; a spray tube disposed adjacent the upper end of the evaporator case and above the evaporator; The ice maker of claim 1 , wherein the spray tube includes a lever arm engaged with the evaporator bracket.

10. the evaporator is secured to a plurality of integrally formed evaporator brackets; 2. The ice maker of claim 1, wherein each of the first and second evaporator walls of the evaporator case defines a watertight pocket in an interior shelf, and a tab of each of the evaporator brackets is received within the watertight pocket of a corresponding one of the first and second evaporator walls.

11. a top insulation facing a top end of the evaporator and received between a first evaporator wall and a second evaporator wall of the evaporator case; the top insulation includes tabs extending from opposite sides of an insulation front end of the top insulation; each of the tabs is received within a notch defined in each of the first evaporator wall and the second evaporator wall; 2. The ice maker of claim 1, wherein said tabs secure said top insulation to said first evaporator wall and said second evaporator wall.

12. an electrical circuit including a main controller; a cooling circuit including the evaporator; and a water circuit, The water circuit includes: an inlet water valve configured to receive and regulate water entering the ice maker; a drain valve configured to receive and regulate water exiting the ice maker; a cleaning valve disposed between the inlet water valve and the drain valve; each of the inlet water valve, the drain valve, and the cleaning valve is in electrical communication with and controlled by the main controller; 2. The ice maker of claim 1, wherein water in the water circuit is configured to make ice during an ice formation cycle and to clean the evaporator during a cleaning cycle by operation of the inlet water valve, the drain valve, and the cleaning valve, respectively, by the main controller.

13. Assembling the inner panels of the evaporator case together with snap-fit ​​joints by inserting a tab of each snap-fit ​​joint into a corresponding slot of the snap-fit ​​joint; forming a foam-tight and water-tight seal at a seam defined by a connection between said inner panels; assembling a plurality of outer panels to the inner panel with slide joints by inserting a lip of each slide joint into a corresponding groove of the slide joint, the grooves being at least partially defined by one of a plurality of tapered protrusions defined in each of the inner panels; insulating the evaporator case with foam insulation disposed within an insulation cavity defined by a plurality of the outer panels and a plurality of the inner panels; A method for manufacturing an ice cream maker, comprising:

14. forming a protrusion on a tank defining a bottom of the evaporator case, the protrusion extending perpendicularly from the tank and being integrally formed therewith; Fixing a float switch to a float switch mounting base; a float switch mount fixed to the protruding portion, the float switch mount facing both sides of the protruding portion after assembly, the float switch configured to sense a water level in the tank; The method of claim 13 further comprising:

15. the outer panel and the inner panel together define a plurality of overflow insulation cavities, the upstanding ribs and walls of the inner panel and the tabs of the outer panel defining each of the plurality of overflow insulation cavities; The method includes the steps of: contacting an inner surface of the outer panel with the upstanding rib of the inner panel to define a primary seal; restricting a flow of the foam insulation from the insulation cavity to the overflow insulation cavity; the overflow insulation cavity is isolated from the insulation cavity except for a pair of gaps; a first gap of the pair of gaps is provided at least in part at a first end of the upstanding rib by a first sloped protrusion; a second gap of the pair of gaps is provided at least in part at a second end of the upstanding rib by a second sloped protrusion; The manufacturing method of claim 13, wherein a cross-sectional area of ​​the overflow insulation cavity in each of the first gap and the second gap is smaller than a cross-sectional area of ​​the overflow insulation cavity at a position offset from each of the first gap and the second gap.

16. 1. A method of using an ice cream maker, comprising: forming ice on an evaporator of the ice maker, the evaporator being housed within an evaporator case of the ice maker; Recovering the ice from the evaporator; and and cleaning the evaporator. Cleaning the evaporator comprises: activating a switch on the ice maker in a first manual intervention of the overall cleaning procedure to initiate the overall cleaning procedure; sounding an audible alarm to notify a user that a second manual intervention is required; pouring a cleaning fluid into a tank of the evaporator case during the second manual intervention; automatically initiating and completing one of a cleaning phase and a sanitizing phase upon completion of the second manual intervention, the automatically initiating one of the cleaning phase and the sanitizing phase including operating a cleaning valve in a water circuit of the ice maker by a main controller of the ice maker; and automatically initiating and completing a rinse phase.

17. Removing a fastener securing a portion of an outer casing of the ice cream maker; 17. The method of claim 16, further comprising: providing tool-less access to a spout of the tank of the evaporator case by the user from a front of the ice maker by only removing the one fastener.

18. Pouring the cleaning fluid into the tank includes pouring the cleaning fluid into a spout disposed within the tank of the evaporator case, the spout sloping downwardly from a front end of the tank relative to a horizontal orientation; The method of claim 16 , further comprising directing the cleaning fluid to a water reservoir defined by the tank.

19. causing a water pump of the ice maker to pulsate water exiting the water pump; 17. The method of claim 16, further comprising delivering the water in a pulsating manner through the water circuit of the ice maker to the evaporator to facilitate cleaning of the evaporator.

20. 17. The method of claim 16, further comprising maintaining all hoses of the water circuit connected during the overall cleaning procedure.

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