Ice maker

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 on August 3, 2018, and U.S. Provisional Patent Application No. 62 / 714,412, filed on August 3, 2018. Both are hereby incorporated by reference in their entirety into this specification.

[0002] This disclosure relates to ice makers. More specifically, this disclosure relates to ice makers having an ice maker and a storage container, particularly an ice maker incorporating a snap - fit or slide - fit evaporator case assembly using integrally - formed components, and to more rationalized cleaning methods thereof.

Background Art

[0003] Typical ice makers, particularly commercial ice makers configured to continuously produce large amounts of ice for hours, days, and years, have at least four circuits without considering the structure of the ice maker itself, namely, a cooling circuit for circulating refrigerant, and in some embodiments as part of the cooling circuit, an air circuit or a water circuit for circulating cooling air or water within the cooling circuit, a water circuit for circulating water to form ice and sometimes to clean the ice maker, and an electrical circuit for circulating electric current. Generally, it is important to separate the three circuits, for example, water in any water circuit must not leak into the electrical circuit or into the foam insulation wall of the cooling circuit, hot air must not leak into the area where cooling air and water promote ice formation, and electricity must not leak into water (and vice versa). When assembling the ice maker to an ice storage container, even more complexity is introduced. It can be advantageous to consistently and firmly assemble various sub - components of the ice maker while separating them appropriately to promote a harmonious interaction between these various circuits while separating them.

[0004] The considerations required to build an ice maker that can withstand the harsh environments in which it often operates can add significant costs and complexity to the ice maker and its use. For example, using additional materials and fasteners to join or assemble ice maker components can require significantly more labor and specialized skills. Furthermore, ice maker cleaning procedures that do not take these factors into account may require manual intervention by the user, potentially diverting the user from other tasks. [Overview of the project] [Means for solving the problem]

[0005] It should be understood that this summary of the invention is not an exhaustive summary of the disclosure. This summary is illustrative and not limiting, and is not intended to identify or elaborate on the main or important elements of the disclosure. The sole purpose of this summary is to explain and illustrate certain concepts of the disclosure as an introduction to the following complete and exhaustive detailed description.

[0006] Disclosed is an ice maker comprising an evaporator case, which includes a dry compartment and a wet compartment adjacent to the dry compartment, and is made to accommodate an evaporator, the evaporator case comprising a plurality of inner panels joined to one another by snap-fit ​​joints, each of which includes a tab and defines a slot, and each of the plurality of joints formed between the inner panels defines a foam-tight and a water-tight seal, and a plurality of outer panels, each of which is joined to the other inner panel of the plurality of inner panels by a slide joint, the evaporator case comprising an ice maker comprising an evaporator case, the evaporator case comprising an evaporator case comprising an evaporator case, which is integrally insulated by blown foam insulation material placed in insulation cavities defined by the plurality of outer panels and the plurality of inner panels, and between the plurality of outer panels and the plurality of inner panels.

[0007] Also disclosed is a method for manufacturing an ice maker, comprising: assembling a plurality of inner panels of an evaporator case by snap-fit ​​joints, by inserting the tabs of each snap-fit ​​joint into corresponding slots of the snap-fit ​​joints; forming foam airtight and watertight seals at the joints defined by the connections between the inner panels; assembling a plurality of outer panels to the inner panels by slide joints, by inserting the lips of each slide joint into corresponding grooves of the slide joints, the grooves being at least partially defined by one of a plurality of sloped projections defined within each inner panel; and insulating the evaporator case with blown foam insulation material placed in insulation cavities defined by the plurality of outer panels and the plurality of inner panels, and between the plurality of outer panels and the plurality of inner panels.

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

[0009] The various implementations described herein may include further systems, methods, features, and advantages that are not specifically disclosed herein but will become apparent to those skilled in the art upon consideration of the following detailed description and accompanying drawings. All such systems, methods, features, and advantages are contained herein and intended to be protected by the accompanying claims. The features and advantages of such implementations may be realized and obtained by the systems, methods, and features specifically shown in the accompanying claims. These and other features will become more fully apparent from the following description and accompanying claims, or may be learned by the implementation of such exemplary implementations described below.

[0010] The accompanying drawings incorporated herein and forming part of this specification illustrate several aspects of this disclosure and, together with the specification, serve to illustrate various principles of this disclosure. The drawings are not necessarily drawn to a fixed scale. Throughout the drawings, corresponding features and components may be indicated by corresponding reference numerals for the purposes of consistency and clarity. [Brief explanation of the drawing]

[0011] [Figure 1] This is a front perspective view of an ice maker, including an ice maker and a storage container, according to one aspect of the present disclosure. [Figure 2A] Figure 1 is a front perspective view of the ice maker with its external casing removed. [Figure 2B] Figure 1 is a front perspective view of the ice maker with the front and upper insulation materials of the evaporator case and the base case cover of the compressor base of the ice maker further removed. [Figure 2C] Figure 1 is a front perspective exploded view of the spray tube, water pump, and other components of the ice maker's water circuit. [Figure 3] Figure 1 is a circuit diagram showing the cooling circuit and water circuit of the ice maker. [Figure 4] Figure 1 is a perspective view of an exemplary ice cube produced by the ice maker shown. [Figure 5A]Figure 2B is a front perspective view of the evaporator case. [Figure 5B] This is a side cross-sectional view of the evaporator case shown in Figure 2B, taken along the line 5B-5B shown in Figure 5A. [Figure 6A] Figure 5A is a perspective view of the float switch inside the tank of the evaporator case. [Figure 6B] Figure 6A is a perspective view of the float switch mounting base. [Figure 6C] Figure 6A is a rear view of the float switch mounting base. [Figure 7] Figure 5A is a detailed cross-sectional view of the evaporator case, showing the lip of the front insulation material engaging with the upper insulation material. [Figure 8] Figure 5A is a detailed cross-sectional view of the evaporator case, showing the lip of the front insulation material engaging with the upper end of the tank. [Figure 9] Figure 5A is a detailed cross-sectional view of the evaporator case, showing that the lip of the evaporator wall of the evaporator case is engaged with the rear end of the insulation material of the upper insulation material. [Figure 10] Figure 5A is a front perspective view of the evaporator case in a partially assembled state with the upper insulation partially removed or detached. [Figure 11] Figure 5A is a front perspective view of the evaporator case, where the upper insulation material is seated in approximately the predetermined position between the evaporator walls and is not yet fixed to the evaporator walls. [Figure 12] Figure 5A is a detailed front perspective view of the evaporator case, with the upper insulation fully seated. [Figure 13] Figure 5A is a front upper perspective view of the evaporator case with the front and upper insulation removed. [Figure 14] This is a detailed front upper perspective view of the evaporator case tank in Figure 5A, taken from detail 14 in Figure 13. [Figure 15] Figure 5A is a top perspective view of the evaporator case with the spray tube removed. [Figure 16] Figure 5A is a front perspective view of the evaporator case with the ice maker's spray tube, water pump, and insulated tube removed. [Figure 17] It is a top view of the spray tube in FIG. 2C. [Figure 18] It is a detailed 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] It is a detailed bottom perspective view of the spray tube of FIG. 17, showing the manifold end and shown in an assembled state with the supply tube of the water circuit. [Figure 20] It is a detailed bottom perspective view of the spray tube of FIG. 17 with the supply tube removed. [Figure 21] It is a side perspective view of the spray tube of FIG. 17. [Figure 22] It is a detailed front perspective view of the evaporator case of FIG. 5A, showing the upper heat insulation material, the evaporator bracket, and the evaporator wall. [Figure 23] It 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] It is a detailed perspective view of the evaporator case of FIG. 5A, showing the first pocket of the evaporator wall of FIG. 23. [Figure 25] It is an upward bottom perspective view of the evaporator bracket of FIG. 22. [Figure 26] It is a detailed front corner perspective view of the ice maker of FIG. 1 before assembly of the evaporator case, with the front panel assembly of the outer casing removed. [Figure 27] It is a detailed perspective view of the ice maker of FIG. 26, focusing on the upper end of the panel of the left side panel of the evaporator case. [Figure 28A] It is a perspective view of the second pocket of the evaporator wall of the evaporator case of FIG. 5A. [Figure 28B] It is a detailed cross-sectional view of the evaporator case of FIG. 5A, showing the upper end of the panel of the left side panel assembled to the evaporator wall, taken from line 28B - 28B of FIG. 28A. [Figure 29A]Figure 5A is a detailed perspective view of the evaporator case, showing the groove defined by the horizontal lip at the bottom of the left side panel of the evaporator case and the base of the tank. [Figure 29B] This is a detailed cross-sectional view of the evaporator case in Figure 5A, taken from line 29B-29B in Figure 29A, showing the lower edge of the left side panel mounted on the evaporator wall of the evaporator case. [Figure 29C] Figure 1 is a detailed perspective view of a portion of the interior of a typical embodiment of an ice maker's insulated wall. [Figure 29D] Figure 5A is a cross-sectional perspective view of the evaporator compartment of the evaporator case, viewed from the back panel of the evaporator case. [Figure 29E] This is an upper cross-sectional perspective view of the evaporator compartment, looking towards the tank. [Figure 30] Figure 5A is a top view of the tank base of the evaporator case. [Figure 31] Figure 5A shows the evaporator case with the rear panel and internal side panels attached, and Figure 2B shows the rear perspective view of the compressor base liner. [Figure 32] Figure 5A is an exploded perspective view of the evaporator case, specifically the evaporator wall and the upper front of the tank. [Figure 33] This is a detailed front exploded perspective view of the lower end of the tank and evaporator wall, taken from detail 33 in Figure 32. [Figure 34] Figure 5A is a detailed exploded perspective view of the evaporator case, specifically the tank and the lower end of the evaporator wall. [Figure 35] This is a detailed perspective view of the lower end of the evaporator wall and the upper end of the tank, which are fixed to each other. [Figure 36A] Figure 5A is a disassembled perspective view of the rear view of the evaporator wall and tank of the evaporator case during assembly. [Figure 36B] Figure 36 is a rear perspective view of the evaporator wall and tank after assembly. [Figure 37A] This is a detailed cross-sectional view of the lip at the lower end of the evaporator wall, which engages with the groove at the upper end of the tank of the tank in Figure 34, at the location of the tab-slot combination. [Figure 37B]This is a detailed cross-sectional view of the structure shown in Figure 37A at the location of the tab-slot combination. [Figure 38] Figure 1 is a bottom perspective view of the lower end of the ice maker. [Figure 39] Figure 1 is a front view of the ice maker. [Figure 40] Figure 1 is a front perspective view of the ice maker with the front panel assembly removed, exposing the control box. [Figure 41] Figure 1 is an operation flowchart showing the overall operation of the ice maker controller. [Figure 42] Figure 1 is a first cleaning flowchart showing the first step in either the cleaning or disinfection process of the ice maker. [Figure 43] Figure 1 is a second cleaning flowchart showing the second stage in either the cleaning or disinfection process of the ice maker. [Modes for carrying out the invention]

[0012] This disclosure can be more readily understood by referring to the following detailed description, examples, drawings, and claims, as well as the preceding and following descriptions. However, prior to the disclosure and description of the devices, systems and / or methods, it should be understood that this disclosure is not limited to, and therefore can be modified, unless otherwise indicated. It should also be understood that the technical terms used herein are for the sole purpose of describing specific embodiments and not for limitation.

[0013] The following description provides possible teachings of the device, system, and / or method in its best known form. For this purpose, those skilled in the art will recognize and understand that many modifications can be made to the various forms of the device, system, and / or method described herein, while still obtaining the beneficial results of the disclosure. It will also be apparent that some of the desired advantages of the disclosure can be obtained by selecting some of the features of the disclosure without using other features. Accordingly, those skilled in the art will recognize that many modifications and alterations to the disclosure are possible, and in fact desirable in certain circumstances, and are part of the disclosure. Accordingly, the following description is provided as an illustration of the principles of the disclosure, and not limiting them.

[0014] As used throughout, the singular forms “a,” “an,” and “the” include plural referents unless otherwise explicitly indicated in the context. Therefore, for example, a reference to “an element” may include two or more such elements unless otherwise indicated in the context. In addition, any element described herein may be a first such element, a second such element, etc. (for example, a first widget and a second widget even when only “widget” is referred to).

[0015] In this specification, a range may be expressed as "about" one specific value and / or "about" another specific value. When such a range is expressed, another aspect includes "about" one specific value and / or other specific values. Similarly, when a value is expressed as an approximation using the preposition "about" or "substantially," it will be understood that the specific values ​​constitute another aspect. It will be further understood that each range endpoint is significant both with respect to other endpoints and independently of other endpoints.

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

[0017] As used herein, the terms “optional” or “optionally” mean that the following events or circumstances may or may not occur, and that such descriptions include examples of events or circumstances in which such events or circumstances may occur and examples of circumstances in which such events or circumstances may not occur.

[0018] As used herein, the word "or" means any one component of a given list, and includes any combination of components 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 may be used to carry out the disclosed methods and systems. These and other components are disclosed herein, and combinations, subsets, interactions, groups, etc., of these components are disclosed, while specific references to each of these various individual and collective combinations and permutations are not expressly disclosed. It is understood that for all methods and systems, each one 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. Accordingly, it is understood that where there are various additional steps that may be carried out, each of these additional steps may be carried out in conjunction with any particular aspect or combination of aspects of the disclosed methods.

[0020] To simplify the description of the various elements disclosed herein, the rules of “left,” “right,” “front,” “rear,” “top,” “bottom,” “upper,” “lower,” “inside,” “outside,” “inboard,” “outboard,” “horizontal,” and / or “vertical” may be referred to. Unless otherwise specified, “front” refers to the end of the ice maker closest to and occupied by the user of the ice maker; “rear” is the opposite or distal end of the front; “left” is the left side or the side facing left of a person standing in front of the ice maker and facing the front; and “right” is the right side or the side facing right of the same person. “Horizontal” or “horizontal orientation” refers to being in a plane that extends from left to right and is aligned with the horizon. "Vertical" or "vertical orientation" refers to being in a plane that forms a 90-degree angle with the horizontal.

[0021] Disclosed are ice makers, as well as related methods, systems, devices, and various apparatus. An ice maker may include an ice maker and a storage container. Those skilled in the art will understand that the disclosed ice makers are described in only a few exemplary forms among many. No particular terminology or description should be considered to limit the scope of this disclosure or any claims arising therefrom.

[0022] Figure 1 is a front perspective view of an ice maker 100 according to one embodiment of the present disclosure. The ice maker 100 may include an ice maker 110 and a storage container 190. The ice maker 110 may be configured to produce ice, which may be supplied downward to the storage container 190 by gravity. The storage container 190 may be insulated to maintain a low temperature within the storage container compartment and to prevent the ice from melting. In some embodiments, the storage container 190 may be cooled, and in other embodiments, the storage container 190 may not be cooled.

[0023] The ice maker 110 may include an external casing 120, which may be configured to house the ice maker 110 and its internal components. As shown in the illustration, the external casing may include a front panel assembly 122. The front panel assembly 122 may extend from the upper end 112 to the lower end 114 of the ice maker 110, and from the left side 116a to the 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 to the ice maker 110 in the form of clean air from outside the ice maker 110.

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

[0025] Figure 2A is a front perspective view of the ice maker 110 of Figure 1 with the external casing 120 (shown in Figure 1) removed. In this embodiment, the ice maker 110 may be an air-cooled model that can be cooled, for example, by circulating air into the external casing 120 through an air inlet opening 180 (shown in Figure 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 can be configured to circulate air within the ice maker 110. The ice maker 110 and its body 200 may be partitioned into a wet compartment 202 and a dry compartment 204 below or inside the external casing 120, and may further include a frame 201 and a base case 205. The wet compartment 202 may be mainly defined by an insulated evaporator case 206. The evaporator case 206 can house most of the components of the water circuit 450 (shown in Figure 3) of the ice maker 110, which can be configured to form ice from liquid water that is sent to and circulates within the ice maker 110. The evaporator compartment 306 (shown in Figure 2B) of the evaporator case 206 can be insulated. The evaporator case 206 may include, for example, a removable front insulation 208 and a removable upper insulation 210 that can partially house and insulate the evaporator compartment 306. Either the front insulation 208 or the upper insulation 210 may be a panel or an insulating panel. In addition, as will be further described below, the tank 214 (which may be a water tank) and the evaporator walls 207a, b (207a is shown in Figure 2B) of the evaporator case 206 may be insulated integrally. "Integically insulated" means that liquid foam insulation can be filled into the walls of the ice maker 110 while the ice maker 110 or its insulation portion is supported within a foam molding jig or mold. Such insulation may be, for example, a water-foamed or refrigerant-foamed high-pressure or low-pressure foam that flows through the walls of the ice maker 110, solidifies, and hardens, causing the walls to exhibit thermal insulation properties. The pressure of such foam may reach above 14 psi or atmospheric pressure.Each of the following panels that form part of the interior of the evaporator case 206 or base case 205 may be an inner panel: the tank 214, the evaporator walls 207a, b, and any other panels that form part of the interior of the evaporator case 206 or base case 205, such as, for example, the molded inner panel of the compressor base 226 shown in Figure 31.

[0026] The water circuit 450 may include a water pump 212 that can be mounted on or adjacent to the tank 214 at a location outside the evaporator compartment 306. A portion of the tank 214 housing 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 upward from the tank 214 into the evaporator compartment 306 where water can form ice.

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

[0028] The ultrasonic container sensor 290 can be installed within the drying compartment 204 and can also extend into the compressor base 226. The ultrasonic container sensor 290 may be configured to monitor the level of ice cubes 490 (shown in Figure 4) accumulated in the storage container 190 (shown in Figure 1). The ultrasonic container sensor 290 can 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 the level position defined by the outlet of the ultrasonic container sensor 290 to the 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 can communicate electronically with the control box 230. When the level of ice cubes 490 in the storage container 190 reaches a stop height which may be a desired and predetermined value set by the technician or user of the ice maker 110, the control box 230 can receive a signal from the ultrasonic container sensor 290 and stop the ice-making process, thereby stopping the further production of ice cubes 490. As the ice melts or is removed from the storage container 190, the level may reach the replenishment height. When the level of ice cubes 490 in the storage container 190 reaches the replenishment height, the ultrasonic container sensor 290 can send a signal to the control box 230, which can restart the ice-making process to replenish the storage container 190 with ice cubes 490. The "full" height or level may be a desired and predetermined value set by the technician or user of the ice maker 110, or the "full" height may be programmed into the controller 232.

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

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

[0031] Figure 2C shows a front perspective exploded view of the spray tube 312, 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 can 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 can fluidly communicate with water entering the ice maker 110 at a water inlet 372 and passing through the inlet water valve inlet pipe 364. The water circuit 450 may include a drain pipe or drain hose 366 which can be coupled to the drain valve 356 by a drain valve outlet pipe 368 and can allow water to be discharged from the ice maker 110 at a water outlet 374. The water circuit 450 may include a float switch 690.

[0032] Figure 3 is a circuit diagram showing the interactions and interconnections between the various components of the cooling circuit 400 and the various components of the water circuit 450 of the ice maker 110 in Figure 1.

[0033] Figure 4 shows a perspective view of an ice cube 490 in an exemplary embodiment. In some embodiments, the ice cube 490 can be defined as at least partially crescent-shaped, as shown. In some embodiments, the ice cube 490 can be defined as non-crescent-shaped. The ice cube 490 can have a height H, a width W, and a depth D. In some embodiments, the height H can be about 1.5 inches (about 38.1 mm), the width W can be about 1.125 inches (about 28.6 mm), and the depth D can be about 0.5 inches (about 12.7 mm). In other embodiments, the ice cube 490 can be smaller or larger than any dimensions, and can have various shapes such that the ice cubes 490 are not identical.

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

[0035] The tank 214 may be defined as an outer tank portion 530a and an inner tank portion 530b located opposite the outer tank portion 530a. The inner tank portion 530b may be substantially aligned with the evaporator wall 207b. The tank 214 may include, or be at least partially covered or surrounded by, a removable ice cube guide 550 located close to the upper end 514 of the tank. The ice cube guide 550 may slope downward from the outer tank portion 530a to the inner tank portion 530b. The ice cube guide 550 may lead to an ice cube opening 552 defined by the inner tank portion 530b. The ice cube guide 550 may be slid within the tank 214 by sliding it into the ice cube opening 552 until the ice cube guide 550 is set behind or below the lip 553 of the ice cube opening 552. To remove the ice cube guide 550, it can be lifted over the lip 553 and slid out of the tank 214 through the ice cube opening 552. The ice cube guide 550 may have a hole 551 that facilitates its removal. For example, a user can slide their finger into the hole 551 to help lift the ice cube guide 550 over the lip 553.

[0036] The ice cube guide 550 may be configured to guide ice cubes 490 out of the evaporator case 206 under gravity and out of the ice cube opening 552. The ice cubes 490 that exit through the ice cube opening 552 may be discharged below the compressor base 226 (shown in Figure 2A) and through the bottom opening 3814 (shown in Figure 38). The ice maker 110 (shown in Figure 1) may be positioned above the storage container 190 (shown in Figure 1) so that the opening of the storage container 190 (not shown) can 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, pass through the bottom opening 3814, and enter the opening of the storage container 190 to fill the storage container 190.

[0037] A water reservoir 614 (shown in Figure 5B) can be defined below the ice cube guide 550 and between the outer part 530a and the inner part 530b of the tank. A suction hose 560 can fluidly communicate with the water reservoir 614 via the inner part 530b of the tank and with the water pump 212 to supply water to the water pump 212. Thus, the water pump 212 can discharge water upward through the upper end 514 of the tank and through the insulated pipe 512 to the evaporator compartment 306.

[0038] The evaporator wall 207b can be defined as having a front end 509b and a rear end 510b located on the opposite side of the front end 509b. The front insulation 208 can be positioned at the front end 509b between the evaporator wall 207a and the evaporator wall 207b. The front insulation 208 can be defined as having an upper end 520 and a lower end 521 located on the opposite side of the upper end 520. The upper end 520 can define a lip 620 (shown in Figure 5B) that can engage with the upper insulation 210, and the lower end 521 can define a lip 621 (shown in Figure 5B) that can engage with the upper end 514 of the tank to secure the front insulation 208 to the evaporator case 206. The upper insulation 210 can be removed in order to remove the front insulation 208, and thus the upper insulation 520 can be rotated away from the front end 509b while the lower end 521 of the insulation is swung around the upper end 514 of the tank 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 upper insulation 520 away from the front end 509b. With the upper insulation 210 fully installed, the forward movement of the pull tab 522 allows the lip 620 to grip and push the upper insulation 210, thereby facilitating its removal. The engagement between the front insulation 208 and the upper insulation 210 and the upper end 514 of the tank, including the lips 620 and 621, is further shown in Figure 5B.

[0039] Figure 5B is a side cross-sectional view of the evaporator case 206 of Figure 2B, taken along the line 5B-5B shown in Figure 5A. This cross-sectional plane can substantially divide the insulated tube 512 into two. The upper insulation material 210 can be defined as an insulation material front end 610 and an insulation material rear end 612 located opposite the insulation material front end 610. The insulation material rear end 612 can 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 Figure 5A). The evaporator wall 207a can be further defined as a front end 509a, a rear end 510b, and a wall lower end 508a, which may correspond to the wall front end 509b, rear end 510b, and wall lower end 508b (each shown in Figure 5A) of the evaporator wall 207b. As shown in the illustration and as described below with respect to Figures 10 to 12, the front end 610 of the insulation material can be fixed to the evaporator walls 207a and 207b.

[0040] The insulated tube 512 can carry water from the water pump 212 to the spray tube 312. The spray tube 312 can extend from a front end 509a to a rear end 510a and can be configured to spray water downward from various points along its length into a series of channels 640 defined by the evaporator plate 650 of the evaporator 310. The evaporator 310 may further include a tube 652 that runs in a meandering path between the evaporator plate 650 and adjacent evaporator plates 650, thereby facilitating heat exchange between the tube 652 and adjacent and opposing evaporator plates 650. As the liquid refrigerant flowing through the evaporator 310 begins to evaporate into a gaseous state, the refrigerant absorbs heat from the water sprayed by the spray tube 312 to the outside of the evaporator plate 650, thereby forming ice cubes 490 (shown in Figure 4) within the channels 640. When the ice cubes 490 become large enough (which can be determined by the passage of a predetermined ice-making interval during the ice-forming cycle), the ice cubes 490 can be removed from the evaporator by starting the recovery cycle. While the evaporator 310 is being heated 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 can define an opening so 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 can pass through the ice cube guide 550 back to the water reservoir 614.

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

[0042] As shown in the figure, the evaporator case 206 may further include a tank base 602. The tank base 602 may define a split collar 604 which can be configured to receive and frictionally engage with a support column 606 defined by the tank 214. The frictional engagement between the support column 606 and the split collar 604 facilitates the assembly of the evaporator case 206 by providing a tool-less, push-together connection.

[0043] Figure 6A is a perspective view of a float switch 690 inside a tank 214. The float switch 690 may be mounted on a float switch mounting base 691. The float switch mounting base 691 may include a support arm 692 and a mounting bracket 694. The support arm 692 may define an opening 693 (shown in Figure 6B), and the float switch 690 may be secured through the opening 693 by a nut or other fastener. The mounting bracket 694 may define a mounting channel 695. The mounting channel 695 can receive a projection 696 defined by the tank 214. The tank 214 may be formed by injection molding, and one of the advantages of injection molding is the ability to form detailed features such as the projection 696, the boss 1050 (shown in Figure 10), and other features of the evaporator case 206 as described herein integrally, i.e., seamlessly, rather than attaching them as separate components. "Monolithic" means that it is cast, molded, or formed as a single piece. More specifically, each monolithic component can be formed from a single material in a single operation without any welds or mechanical connections, such as threading, flanges, fasteners, interlocking fits, adhesives, brazing, soldering, or other mechanical connection methods, to join the features that are described as being monolithic or formed in a monolithic manner. The projection 696 may be slightly tapered upward, and the mounting channel 695 may define a complementary shape for securely fastening the float switch mounting base 691 to the projection 696.

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

[0045] Figure 6C is a rear view of the float switch mounting base 691 facing the mounting bracket 694. As shown, the latching arm 698 can define at least partially the 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 may be configured to engage with a pocket 697 (shown in Figure 6B) to fix and secure the position of the mounting bracket 694 horizontally and vertically on the projection 696 (shown in Figure 6B).

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

[0047] Figures 10 to 12 show the upper insulation material 210 slid into a predetermined position between the evaporator wall 207a and the evaporator wall 207b. In Figure 10, the rear end 612 of the upper insulation material 210 can be positioned between the evaporator wall 207a and the evaporator wall 207b, and the front end 610 can extend laterally outward from between the evaporator wall 207a and the evaporator wall 207b. The upper insulation material 210 can define a pair of rails that can extend longitudinally along each side of the upper insulation material 210, as indicated by the rail 1010 on one side of the upper insulation material 210.

[0048] Figure 11 shows an upper insulation material 210 that is seated in approximately a predetermined position between evaporator walls 207a and 207b, but is not yet fixed to the evaporator walls 207a and 207b. As shown by rail 1010, a pair of rails can be placed along the upper wall ends 507a and 207b (507a is shown in Figure 5B) of the evaporator walls 207a and 207b. As shown by evaporator wall 207b, the evaporator walls 207a and 207b can define notches 1107 located near the corners of the upper wall ends 507a and 207b (507a is shown in Figure 5B) and the front ends 509a and 209b (notches defined by evaporator wall 207a are not shown). The notches 1107 can extend laterally inward from the thickness of the front ends 509a and 209b through this thickness. The upper insulation material 210 can have tabs 1110 defined on both sides of the front end portion 610 of the insulation material. In this figure, the tabs 1110 can be aligned with the notch portion 1107, but can also be engaged with and disengaged from the notch portion 1107.

[0049] Figure 12 is a detailed front perspective view of the evaporator case 206 showing the upper insulation material 210 in an installed and fixed configuration. As shown, the upper insulation material 210 can be positioned completely between the evaporator wall 207a and the evaporator wall 207b, and the tab 1110 can be inserted into the notch 1107, thereby fixing the front end 610 of the insulation material to the evaporator walls 207a and b.

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

[0051] The evaporator brackets 1320a and 1320b can support the spray tube 312 and the evaporator 310. The spray tube 312 can define a manifold end 1310 positioned between the evaporator bracket 1320a and the front end 509a and 1320b. The spray tube 312 can also define two tube sections 1312a and 1312b that can be separated 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 an insulated pipe 512, which can redirect water pumped upward from the water pump 212 through the manifold end 1310 to the tube sections 1312a and 1320b. When the ice maker 110 is making ice, the tube sections 1312a and 1312b can spray water downward into the evaporator 310. In contrast, the supply tube 1930 (shown in Figure 2C) can spray water into the evaporator 310 (including the portion of the evaporator 310 into which water does not enter from the spray tube 312) when the ice maker 110 cleans itself during the cleaning or disinfection cycle described below.

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

[0053] Figure 15 is a top perspective view of the evaporator case 206 with the spray tube 312 removed. As shown, the evaporator 310 may include four evaporator plates 650, which can be paired into two evaporator plate assemblies 1550a,b. The evaporator plate assemblies 1550a,b extend between the evaporator brackets 1320a and 1320b to secure the evaporator 310 within the evaporator compartment 306. Two tubing circuits 1552a,b may extend between adjacent evaporator plates 650 of each evaporator plate assembly 1550a,b. The tubing circuits 1552a,b may each consist of meandering patterns extending rearward and forward between the evaporator brackets 1320a and 1320b. The tubing 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 tubing circuits 1552a,b may include copper tubing, and the evaporator plate 650 may include stainless steel. Each evaporator plate assembly 1550a,b can function as a heat exchanger. More specifically, the heat from the evaporator plate 650 is absorbed by evaporating the refrigerant circulating within the tubing circuits 1552a,b, thereby cooling the evaporator 310 to below the freezing point of water.

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

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

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

[0057] Figure 17 is a top view of the spray tube 312 of Figure 3. The spray tube 312 may include a pair of lever arms 1712a, b, each of which can be attached to a different of the opposing tube sections 1312a, b. The lever arms 1712a, b may be elastic and flexible, and may be biased to extend outward from each tube section 1312a, b toward the manifold end 1310. Each lever arm 1712a, b may define engaging notches 1714a, b and ends 1716a, b. The spray tube 312 may also include a pair of caps 1710a, b that can seal the tube sections 1312a, b on the opposite side of the manifold end 1310.

[0058] Figure 18 is a detailed front perspective view of the evaporator case 206, focusing on the manifold end 1310 of the spray tube 312 in Figure 3. As previously mentioned, each tube section 1312a, b can extend through a different of the tube openings 1612a, b, and the evaporator bracket 1310a can support the manifold end 1310 of the spray tube 312. Lever arms 1712a, b can also extend through the tube openings 1612a, b, along with each mounted tube section 1312a, b. Engaging notches 1714a, b can engage with the edges of different of the tube openings 1612a, b, thereby securing the spray tube 312 to the evaporator bracket 1310a laterally and preventing the tube sections 1312a, b from coming out of the tube openings 1612a, b. The lever arms 1712a and 1712b can be engaged with and disengaged from the tube openings 1612a and 1612a by pushing their ends 1716a and 1716b inward toward the manifold end 1310. When the lever arms 1712a and 1712b are engaged with and disengaged from the tube openings 1612a and 1612a, the spray tube 312 can be pulled laterally outward from the evaporator bracket 1310a, for example, to facilitate cleaning or maintenance of the spray tube 312.

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

[0060] As better shown below in Figure 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. In addition, a supply tube 1930 may be located below the spray tube 312. The supply tube 1930 can define a supply manifold end 1940 having a connector 1942. The supply tube 1930 may also include a pair of supply tube portions 1932a,b. Each supply tube portion 1932a,b may extend along one of the tube portions 1312a,b between adjacent rows 1916a-d of channel guides 1914. For example, supply tube portion 1932a may extend along tube portion 1312a between adjacent rows 1916a and 1916b of channel guides 1914. The supply tube sections 1932a and b can each define a plurality of supply nozzles 1934, which can spray cleaning fluid, disinfecting fluid, and water between the evaporator plates 650 (shown in Figure 15) of the evaporator plate assemblies 1550a and b (shown in Figure 15) during cleaning and disinfecting the ice maker, thereby cleaning, disinfecting, and rinsing areas of the evaporator 310 that would otherwise be difficult to clean.

[0061] Figure 20 is a detailed bottom perspective view of the spray tube 312 of Figure 19, excluding the supply tube 1930 and spray guides 1912a, b. As previously mentioned, the spray nozzles 1910 may be arranged in two rows 2012a-d along their respective tube sections 1312a, b. For example, the two rows 2012a, b of the spray nozzles 1910 may extend along tube section 1312a. In addition, the two rows 2016a-d of the guide tabs 2014 may extend along each tube section 1312a, b, and the guide tabs 2014 may be spaced apart between the spray nozzles 1910. The guide tabs 2014 can assist in aligning the spray guides 1912a, b (shown in Figure 19) with the spray nozzles 1910.

[0062] Figure 21 is a side perspective view of the spray tube 312 of Figure 19, excluding the supply tube 1930 and spray guides 1912a and 1912b. As has been typically done conventionally, the spray tube 312 can be formed integrally or seamlessly from a single part using methods such as blow molding. Alternatively, the spray tube 312 may include an upper panel 2112 and a bottom panel 2114. The upper panel 2112 and the bottom panel 2114 may be parts formed separately, for example, by injection molding, etc. The upper panel 2112 and the bottom panel 2114 can be joined to each other by a joint 2116, for example, by techniques such as vibratory welding, etc. Vibratory welding is a quick and chemical-free technique that can weld parts together. The upper panel 2112 and the bottom panel 2114 can be rubbed together under pressure using a vibratory forming tool to create friction, thereby welding the base materials of panels 2112 and 2114 together. The weld can then be cooled.

[0063] In this embodiment, the caps 1710a, b can also be removed from each tube section 1312a, b to expose the end openings 2110a, b. In contrast to blow-molded spray tubes, which typically have small, rough-edged holes defining each end opening 2110a, b, the end openings 2110a, b of the spray tube 312 formed from panels 2112, 2114 may 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 may be configured to cover and securely fit over the end openings 2110a, b without the need for tools to facilitate assembly and maintenance.

[0064] Figure 22 is a detailed front view of the upper 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 upper 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 upper end 507a of the wall. The evaporator bracket 1310a (evaporator bracket 1310b is shown in Figure 13) may be configured to be lifted vertically upward in order to remove the evaporator brackets 1310a and 1310b from between the evaporator walls 207a and 207b. The upper insulation material 210 can be positioned in a way that prevents the evaporator brackets 1310a and 1310b from being lifted vertically.

[0065] Figure 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 detached from the evaporator walls 207a, b. By lifting the evaporator bracket 1310a vertically upward, the vanes 2212a, b can be engaged with and disengaged from a pair of watertight pockets 2307a, b, which are defined and extend to the inner shelves 2207a, b of the evaporator walls 207a, b, respectively. In contrast to the conventional method in which the evaporator walls 207a, b are formed using a vacuum forming method, the pockets 2307a, b can be formed without exposing any blown foam or other insulation material present behind the evaporator walls 207a, b.

[0066] Figure 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 notch 2404 extending inward from the groove 2402 into the evaporator compartment 306. In this embodiment, the evaporator walls 207a,b (207b is shown in Figure 23) can be formed by injection molding, and the pocket 2307a can be integrally formed within the evaporator wall 207a. As proposed 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 an upward bottom perspective view of the evaporator bracket 1310a of Figure 13. As shown, the blade 2212a may define a longitudinal tab 2502 which can be configured to engage with a groove 2402 (shown in Figure 24) and a vertical ridge 2504 which can be configured to engage with a vertical notch 2404 (shown in Figure 24).

[0068] As described above, the evaporator walls 207a and 207b have conventionally been formed from polymer materials such as acrylonitrile butadiene styrene (ABS) using vacuum forming. However, vacuum-formed parts can and inevitably have varying thicknesses throughout the part, and due to varying shrinkage under different manufacturing conditions, the dimensions may vary even more significantly from part to part than those of parts formed using injection molding. After the formation of individual vacuum-formed parts, the parts are typically joined using solvent welding. During solvent welding, a solvent such as acetone, or a monomer mixture containing a solvent such as acetone, and a mixture of the crushed (i.e., reduced to small fragments) raw material (e.g., crushed ABS) forming the parts can be used, for example, without limitation, to soften the material of panels 2112 and 2114, and panels 2112 and 2114 can be pressed together until the material hardens again. While the monomers used in solvent welding can solidify within minutes, a 24-hour curing time is typically required, and the quality of joints joined by solvent welding can vary significantly depending on the skill of the operator assembling components such as the evaporator walls 207a, b and tank 214. Furthermore, solvent welding often involves chemicals that can generate unpleasant vapors during use.

[0069] In contrast, as described above, the evaporator walls 207a and b, as well as the tank 214 of the evaporator case 206, can be individually formed from a material such as ABS or any other desirable and moldable material using a molding method such as injection molding. As described, the components of the evaporator case 206 are then joined very securely to each other without any fasteners or even any solvent welding methods, thereby forming 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. Since the water foam insulation can have a particularly low viscosity, it can remain in a water-like state for more than 10 seconds after being sprayed onto an insulating assembly such as the evaporator case 206, making the watertight and foam-tight joints even more beneficial against water ingress during the operation of the ice maker 110, as well as against water leakage from the seams of the insulating assembly such as the evaporator case 206 during the foam molding process.

[0070] Figure 26 is a detailed front angle perspective view of the ice maker 110 of Figure 1, before assembly of the evaporator case 206, with the front panel assembly 122 (shown in Figure 1) of the external casing 120 removed. As shown, the left side panel 2620 of the external casing 120 is offset outward from the evaporator wall 207a of the evaporator case 206, and the upper panel assembly 2622 of the external casing 120 is offset above the upper insulation 210. The left side panel and any other panels forming part of the outside of the evaporator case 206 or base case 205 may be outer panels.

[0071] Figure 27 is a detailed perspective view of a portion of the ice maker 110 shown in Figure 26, focusing on the upper panel end 2720 of the left side panel 2620. The left side panel 2620 can define a vertical section 2722, a lip 2724 (which may be an upper lip) located at the upper panel end 2720, and a lip 2734 (which may be a side lip) located at the front panel end 2732. The lip 2724 may extend inward toward the evaporator case 206. The evaporator wall 207a can define a groove 2707 extending from the front end 209a to the rear end 210a. The groove 2707 may be defined below the upper wall end 507a. Within the groove 2707, the evaporator wall 207a can define a plurality of upwardly inclined projections 2709 that extend toward the groove 2707 and may be sloped projections. The upwardly inclined projection 2709 can be sloped upward and inward toward the groove 2707. As shown in the figure, the upwardly inclined projection 2709 and the groove bottom wall 2790 that may extend between the upwardly inclined projection 2709 extend the same distance toward the left side panel 2620, and can contact the left side panel 2620 during the foam molding of the assembly, forming a seal toward the left side panel 2620.

[0072] In some embodiments, as illustrated and described, the groove 2707 can be oriented horizontally and the lip 2724 can be oriented horizontally. In other embodiments, the groove 2707 can be oriented vertically and the lip 2724 can be oriented vertically, for example, adjacent to the front end 509a,b (shown in Figure 11) of the evaporator wall 207a,b (207b is shown in Figure 11), without limitation. The groove 2707 can therefore be a horizontal or vertical groove in any part of the evaporator case 206, and the lip 2724 can be a horizontal or vertical lip of any panel. Similarly, other parts of the evaporator case can define grooves 2707 which can be oriented horizontally, vertically, or in any other desired orientation between horizontal and vertical orientations.

[0073] The groove 2707 can be configured to receive a lip 2724 for attaching 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 on an upwardly inclined projection 2709 to a fully seated position, thereby forming a sliding joint. In addition, the left side panel 2620 can define a pair of tabs 2730. In this embodiment, the tabs 2730 can be cut out from the lip 2724 and plastically bent at an inclination upward and away from the lip 2724. As shown below in Figure 28, each of the tabs 2730 can engage with a watertight pocket 2830 defined within the groove 2707. Each of the tabs 2730 can be a lance tab, which can be elastically deformed during assembly, at least together with the lip 2724, but not towards the periphery of the lip 2724, in order to allow insertion of the lip 2724. The tabs 2730, with or without the periphery of the lip 2724, can then elastically deform back to their original position and engage with or with the pocket 2830.

[0074] Figure 28A is a perspective view of the pocket 2830 in the evaporator wall 207a of Figure 2. The pocket 2830 can be defined by the upper surface of a groove 2707, which faces an upwardly inclined projection 2709. The upwardly inclined projection 2709 pushes the lip 2724 (shown in Figure 27) and tab 2730 (shown in Figure 27) upward, engaging with the pocket 2830, and allowing the upper panel end 2720 of the left side panel 2620 to be secured to the evaporator wall 207a. This mounting mechanism can provide a simple snap-fit ​​assembly that requires no tools.

[0075] Figure 28B shows a detailed cross-sectional view of the upper panel portion 2720 of the left side panel 2620, which is assembled to the evaporator wall 207a of the evaporator case 206 in the slide joint described above. A groove 2707 may be defined between the groove upper wall 2760 and the groove bottom wall 2790. As shown, the groove bottom wall 2790 extends outward from the evaporator wall 207a and can contact the vertical portion 2722 of the left side panel 2620, and the groove bottom wall 2790 can serve as a standoff between the evaporator wall 207a and the left side panel 2620, defining the flat portion of the upright rib 2884, similar to the upright rib 2984 (shown in Figure 29B) described below. A cavity for insulation material 2792 may 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. Overflow insulation cavities 2794 can 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] Tab 2730 can be formed by shearing a portion of lip 2724 and slightly bending a portion of it inward so that a watertight and foam-tight closed lance is formed. As shown in the figure, the shearing and bending of lip 2724 to form tab 130 can be stopped before extending to the entire thickness of the lip 2724 material. Even when an open lance is used, the opening of tab 2730 can be sized such that excess foam that has reached the overflow insulation cavity 2794 does not easily pass through the opening.

[0077] As described above, the liquid foam can be sprayed or injected into the insulation cavity 2792, and the liquid foam can expand and solidify as it hardens. To completely insulate the evaporator case 206 (shown in Figure 2), the insulation cavity 2792 can be completely filled with the liquid foam under pressure. It can be difficult to fill the insulation cavity 2792 precisely without slightly underfilling it, which would leave voids in the insulation, or without slightly overfilling it (in which case the excess insulation may leak out of the insulation cavity 2792). Without compromising the aesthetics of the ice maker 100 (shown in Figure 1) by exposing the foam insulation that has passed through the external casing 120 (shown in Figure 1), the overflow insulation cavity 2794 can provide space for overfilled foam to slowly leak in and expand (but only on the inside of the wall, as described below). For example, the insulation cavity 2792 may, if desired, be intentionally overfilled under pressure to prevent voids in the insulation, or the foaming agent, such as the water foam described above, may have low viscosity and still not easily leak out of the assembly during foam molding. Excess foam may partially leak between the vertical section 2722 and the groove bottom wall 2790, and the insulation may expand and solidify in the overflow insulation cavity 2794. The left side panel 2620 can conceal the overflow insulation cavity 2794 so that the user cannot see the foam that has leaked into the overflow insulation cavity 2794. The improved embodiments described herein can also reduce or eliminate the amount of time required before foam molding to prepare the foamed portion of the ice maker 110 for foam molding or after foam molding to clean up leaked foam.

[0078] Such movement of excess foam into the overflow insulation cavity 2794 can be limited by 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 inclined projection 2709. The gap 2708 can be represented as the entrance to the overflow insulation cavity 2794. Resistance to foam leakage into the overflow insulation cavity 2794 can also be provided by a seal between the inner surface 2623 of the left side panel 2620 and the groove bottom wall 2790 and the upwardly inclined projection 2709, respectively, along the width of the left side panel 2620. 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 the upwardly inclined projection 2709, the excess foam can only move within the gap 2708. 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 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, ensure uniform pressure between the left side panel 2620 and the groove bottom wall 2790 and the upwardly inclined projection 2709, respectively, even if there are variations due to manufacturing tolerances, for example, the width of the lip 2724 or any dimensions of other parts, and these variations can be absorbed by the offset 2890 or offset 2870.

[0079] By positioning the lip 2724 very close to the groove wall 2760 via the upwardly inclined projection 2709, it is possible to prevent the expanding insulation entering the overflow insulation cavity 2794 from leaking out between the lip 2724 of the left side panel 2620 and the groove wall 2760 of the evaporator wall 207a. In addition, the interface between the lip 2724 and the internal sealing lip 2780 can provide additional protection to prevent the foam from leaking out between the lip 2724 and the groove wall 2760. The internal sealing lip 2780 may extend between adjacent upwardly inclined projections 2709, and the lip 2724 may be positioned at least partially between the internal sealing lip 2780 and the groove wall 2760. These features eliminate the need for the assembler to tape, seal, or putty the joint between the left side panel 2620 and the evaporator wall 207a (in any case, these measures may not be effective in preventing leakage from the joint defined between the left side panel 2620 and the evaporator wall 207a, although they may be at least partially effective for some blown foams). Eliminating the need to tape, seal, or putty the joint saves a considerable amount of time during the assembly and foaming of the insulation cavity 2794.

[0080] Figure 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 groove 2707 (shown in Figure 27), the tank base 602 can define a number of downwardly inclined projections 2909 that slope downward and inward toward groove 2907, which may be inclined projections. The downwardly inclined projections 2909 can guide the bottom lip 2920 into a fully seated position within groove 2907. In addition, the bottom lip 2920 can define a tab 2730 that can engage with a watertight pocket 3030 (shown in Figure 30) similar to pocket 2830 (shown in Figure 28A), which is shown facing groove 2907. As shown in the figure, the downward-sloping projection 2909 and the groove wall 2990 that may extend between the downward-sloping projection 2909 extend the same distance toward the left side panel 2620, and during the foam molding of the assembly, they can come into contact with the left side panel 2620 and form a seal with respect to the left side panel 2620.

[0081] As described above, at least in relation to Figure 5B, the tank base 602 can define a split collar 604 which may be configured to receive and frictionally engage with a support column 606 defined by the tank 214. The split collar 604 may define a division 2904 and may be configured to elastically flex radially outward to receive and frictionally engage with the support column 606.

[0082] Figure 29B shows a detailed cross-sectional view of the lower end of the left side panel 2620, which is assembled to the tank base 602 in another slide joint. Similar to the embodiment in Figure 28B, in this embodiment, an overflow insulation cavity 2994 may be defined between the left side panel 2620 and the tank base 602. A groove 2907 may be defined between the groove upper wall 2990 and the groove bottom wall 2960. As shown, the groove upper wall 2990 extends outward from the tank base 602 and can contact the vertical portion 2722 of the left side panel 2620. The insulation cavity 2792 may be defined above the groove upper wall 2990 and inward from the vertical portion 2722 of the left side panel 2620. The overflow insulation cavity 2994 may be defined below the groove upper 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 inclined projection 2909 in Figure 29B) may be configured to allow control of the overflow of excess foam insulation sprayed into the insulation cavity 2994, similar to the insulation cavity 2792 (shown in Figure 28B). The tab 2730 is shown engaged with the pocket 3030.

[0083] The downward-sloping projection 2909 positions the bottom lip 2920 very close to the groove bottom wall 2960, preventing 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 internal sealing lip 2980, similar to the internal sealing lip 2780 in Figure 27B, can provide additional protection to prevent the foam from leaking out between the bottom lip 2920 and the groove bottom wall 2960. As with other parts of the evaporator case 206, including the structure shown in Figure 28B, the movement of excess foam into the overflow insulation cavity 2994 can 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 downward-sloping projection 2909. The gap 2908 can be described as an inlet to the overflow insulation cavity 2994. Resistance to foam leakage into the overflow insulation cavity 2794 may also be provided by a seal between the inner surface 2623 of the left side panel 2620 and the grooved upper wall 2990 and the downward-sloping projection 2909, along the width of the left side panel 2620. Under pressure from the walls of the foam molding jig, sufficient to hold the left side panel 2620 against the grooved upper wall 2990 and the downward-sloping projection 2909, excess foam can move only within the gap 2908. 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 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, ensure uniform pressure between the left side panel 2620 and the groove upper wall 2990 and the downwardly inclined projection 2909, respectively, even if there are variations due to manufacturing tolerances, for example, the width of the lip 2920 or any dimensions of other parts, and these variations can be absorbed by the offset 2990 or offset 2970.

[0084] Figure 29C is a detailed perspective view of a general embodiment of one corner of the evaporator wall 207a, b, or any other part of the evaporator wall 207a, b, showing an internal sealing lip 2982, internal upright ribs 2884, 2984, and an external rib 2986. The internal sealing lip 2982 may be configured to function similarly to the internal sealing lip 2780 and internal sealing lip 2980. The internal upright ribs 2884, 2984 may be configured to function similarly to the groove bottom wall 2790 and groove top wall 2990. The external rib 2986 may be configured to function similarly to the groove top wall 2760 and groove bottom wall 2960. The gaps 2708, 2908 between the internal upright ribs 2884, 2984 (and in particular the sloped projections 2709, 2909 at the ends of the internal upright rib 2984) and the external panel (for example, the left side panel 2620 shown in Figure 29A, which is removed in Figure 29C but offset from the ends of the internal upright ribs 2884, 2984 when assembled to the evaporator wall 207a) can, as described above, limit the flow of foam from the insulation cavity 2792 into the overflow insulation cavities 2794, 2994. In addition, at the corners of the inner panel, such as the evaporator wall 207a, the above structure can prevent foam from leaking through gaps formed at intersections between lips, such as where the lower end of lip 2734 (shown in Figure 27) and the front end of bottom lip 2920 (shown in Figure 29B) meet. As shown in the figure, the dividing line 2900 can be adjusted and positioned as needed on various inner or outer panels across the entire joint of the ice maker 110, dividing feature 2900a and feature 2900b, only their exemplary portions of which are explicitly shown.

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

[0086] Figure 29E is an upper cross-sectional perspective view of the evaporator compartment 306 as seen toward the tank 214. As shown, a fourth portion 2999d of the insulation cavity 2792 may be defined between the back panel 1307 and the rear panel 3120 of the outer casing 120. The rear panel 3120 extends between the internal side panel 2930 and the left side panel 2620 and can accommodate the insulation cavity 2792. The fourth portion 2999d can be joined to the first portion 2999a and the third portion 2999c.

[0087] Figure 30 is a top view of the tank base 602 of Figure 6. The split collar 604 can define a number of radial projections 3004 within the split collar 604. Each radial projection 3004 can define a horizontal shelf-like portion that can support the support 606 (shown in Figure 29) in all three dimensions (X, Y, and Z) when the support 606 is inserted into the split collar 604. The sufficiently wide stance or diameter of the split collar 604 allows the tank 214 to be supported and maintained in position under the significant mechanical and foam pressures that may occur during the foam molding process while the evaporator case 206 and the rest of the ice maker 110 are inside the foam molding jig. By forming multiple radial projections 3004 in a vertical orientation, not only can the manufacturing, particularly the molding, of the tank base 602 be facilitated, but the openings shown within the split collar 604 allow the foam to flow into the split collar 604, ensuring thermal insulation throughout the entire region between the tank base 602 and the tank 214.

[0088] As described above, the tank base 602 can define a pocket 3030. In addition, the tank base 602 can define a pocket 3030 near the rear end 3014 of the base 602, and the pocket 3030 may be configured to receive the rear panel 3120 (shown in Figure 31) by a mounting mechanism similar to that described above for the left side panel 2620 (shown in Figure 26) as shown in Figures 26 to 29. Any thin metal sheet or similar thin panel 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 may also define a discharge channel 3010 and a drain port 3012 leading to the rear end 3014 of the tank base 602. The discharge channel 3010 may be configured to recover water from a drain port 1662 (shown in Figure 16) in a pressurized compartment 1660 (shown in Figure 16) where a water pump 212 (shown in Figure 2) may be located.

[0090] Figure 31 is a rear perspective view of the evaporator case 206 and the liner of the compressor base 226, showing the rear panel 3120 and the internal side panel 2930 attached to the evaporator case 206. The rear panel 3120 and the internal side panel 2930 can be attached to the evaporator case 206, as similarly described for the left side panel 2620 (shown in Figure 26) in Figures 26 to 29. As shown, a pair of bosses 3106 on the evaporator wall 207b can extend into the internal side panel 2930. As shown, the compressor base 226 can define a plurality of downwardly inclined projections 3109, similar to the downwardly inclined projection 2909, which can be sloped downward and inward. The downwardly inclined projections 2909 may be configured to frictionally engage with the right side panel (not shown) of the external casing 120 (shown in Figure 1).

[0091] Multiple outer panels, such as the left side panel 2620 (shown in Figure 28B), and multiple inner panels, such as the evaporator wall 207a (shown in Figure 28B), can define multiple overflow insulation cavities 2794, 2994 (2794 is shown in Figure 28B, and 2994 is shown in Figure 29B). The upright ribs 2884, 2984 (shown in Figure 28B) and wall bodies 2850, 2950 (2850 is shown in Figure 28B, and 2950 is shown in Figure 29B) of the inner panels, and the outer surface 2621 (shown in Figure 28B) of the outer panels can each define one of the multiple overflow insulation cavities 2794, 2994. In each overflow insulation cavity 2794, 2994, the outer surface 2621 of the outer panel can contact the upright ribs 2884, 2984 of the inner panel 261, thereby defining a seal between them. The flow of blown foam insulation from the insulation cavity 2792 to each overflow insulation cavity 2794, 2994 can be restricted by isolating the overflow insulation cavities 2794, 2994 from the insulation cavity 2792, except for a pair of gaps 2708, 2908. The first gap 2708 of the pair of gaps 2708, 2908 can be defined at least partially by the first sloped projections 2709, 2909 at the first end of the upright ribs 2884, 2984. The second gap 2908 of the pair of gaps 2708, 2908 can be defined at least partially by the second sloped projections 2709, 2909 at the second ends of the upright ribs 2884, 2984. The cross-sectional area of ​​the overflow insulation cavities 2794, 2994 in each of the first gap 2709 and the second gap 2909 may be smaller than the cross-sectional area of ​​the overflow insulation cavities 2794, 2994 at positions offset from each of the first gap 2708 and the second gap 2908.

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

[0093] Figure 33 is a detailed front upper exploded perspective view of the tank 214 and the lower wall ends 508a, b of the evaporator walls 207a, b. The upper tank end 514 can define a pair of grooves 3314a, b, which can be configured to receive the lower wall ends 508a, b of the respective evaporator walls 207a, b, 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 each groove 3314a, b.

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

[0095] Figure 35 is a detailed perspective view of the lower wall end 508a of the evaporator wall 207a and the upper tank end 514 of the tank 214, which are fixed to each other. In this embodiment, the lip 3414 (shown in Figure 34) can be received in the groove 3314a (shown in Figure 33). By receiving the lip 3414 in the groove 3314a, the tab 3420 can engage with the slot 3320, thereby securing the evaporator wall 207a to the tank 214. The evaporator wall 207b (shown in Figure 33) can similarly be attached to the tank 214. The engagement of the tab 3420 and the slot 3320 provides a snap-together, tool-free assembly that saves time during the assembly process.

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

[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] Figure 37A shows the lip 3414 of the evaporator wall 207a received in a groove 3314a defined within the tank 214, and Figure 37B shows the tab 3420 of the lip 3414 engaged with a slot 3320 in the groove 3314a (shown in Figure 37A). As shown in Figure 36B, the tab 3620 can also engage with a slot 3622 to secure the rear ends 510a,b together, forming the back panel 1307 of the evaporator case 206. Once assembled, the evaporator case 206 can be seated on the upper end 514 of the tank 214 as described above, and the tank 214 can be attached to the evaporator case 206. As desired, for example, any two thicker parts of the evaporator case 206, such as any part of the evaporator walls 207a,b of the evaporator case 206, or more generally, the ice maker 110, can be constructed and joined in the same manner.

[0099] Figure 38 is a bottom perspective view of the maker lower end 114 of the ice maker 110 in Figure 1. As shown, the tank base 602 and the base case 205 can both define the maker lower end 114 and the bottom opening 3814. The bottom opening 3814 can be aligned with an opening (not shown) at the upper end 192 (shown in Figure 1) of the storage container 190 (shown in Figure 1). The ice cubes 490 produced by the ice maker 110 can fall into the storage container 190 through the bottom opening 3814. An ultrasonic container sensor 290 may extend into the compressor base 226 and be positioned above the bottom opening 3814. As previously stated, to measure the level of ice cubes 490 in the storage container 190, the ultrasonic container sensor 290 can transmit ultrasonic waves downward through the bottom opening 3814 into the storage container 190.

[0100] Figure 39 is a front view of the ice maker 110 of Figure 1. The front panel assembly 122 can be held on the ice maker 110 by fasteners 3910, such as screws, located near the lower end 114 of the maker. When the fasteners 3910 are loosened, the front panel assembly 122 can be lifted and removed from the ice maker 110 to provide access for maintenance, cleaning, or any other purpose. By removing one fastener 3910, as described elsewhere in this specification and shown in the figures, it is possible to facilitate tool-free access from the front of the ice maker to the inside of the evaporator case, including the spout 1414.

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

[0102] To clean and disinfect the ice maker 110, the front panel assembly 122 (shown in Figure 39) can first be removed, as illustrated. Unless otherwise specified, this step and any of the following manual steps may be performed by the user or technician of the ice maker 100. The control switch can then be switched to the "off" position for 3 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 3 minutes, the front panel assembly 122 can be removed again, and the control switch 4010 can be switched to the "off" position. The storage container 190 (shown in Figure 1) can then be emptied of ice and, if appropriate, turned off in preparation for cleaning.

[0103] Next, the mode switch 4012 can be switched to the "cleaning" position, and then the control switch 4010 can be moved to the "on" position. At this point, automatic confirmation of the control switch 4010 being switched to the "on" position may be performed by one short beep followed by one long beep three seconds later. After this, the front panel assembly 122 can be replaced. During this time, the water reservoir 614 of the tank 214 (shown in Figure 6) can be automatically drained and refilled by the ice maker 110. The controller 232 of the control box 230 can then emit a beep (which may be in the form of a two-beep sequence, i.e., beep, beep, pause, then repeat), at which point the front panel assembly 122 can be removed and the control switch 4010 can be switched to the "off" position. The front insulation 208 can be removed, and then a certain amount of cleaning fluid, such as 10.4 fl. oz. of Hoshizaki SCALE AWAY cleaning fluid, can be poured into the water reservoir 614 through the spout 1414 (shown in Figure 14). In some embodiments, the cleaning fluid may contain 5.4 ounces of cleaning agent per gallon. The control switch 4010 can then be switched to the "on" position, at which point automatic confirmation can be performed again by one short beep followed three seconds later by one long beep, and the front panel assembly 122 can be replaced. At this point, the mixture of cleaning fluid and water ("cleaning solution") can be recirculated into the water circuit 450 (shown in Figure 4). To avoid excessive foaming of the cleaning solution, a one-minute delay can be automatically started before each cycle. After the cleaning solution has been automatically circulated into the water circuit 450 for 30 minutes, the ice maker 110 can automatically perform three rinse cycles in succession. When the controller 232 starts beeping again (which may be in the form of a 5-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 Figure 5), float switch 690 (shown in Figure 6), water supply tube, spray tube 312 (shown in Figure 3), and spray guides 1912a, b (shown in Figure 19) can be removed, cleaned, rinsed, and reattached. For example, but not limited to, 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 per gallon of warm water.

[0104] To disinfect the ice maker 110, the mode switch 4012 can be set to the "cleaning" position, and then the control switch 4010 can be moved to the "on" position, at which point automatic confirmation can be performed again by one short beep followed by one long beep 3 seconds later. After that, the front panel assembly 122 can be replaced. During this time, the water reservoir 614 of the tank 214 can be automatically drained and refilled. When the control box 230 starts beeping (which may take the form of the 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 be removed, and then a disinfectant fluid, such as, for example, 0.6 fl. oz. of an 8.25% sodium hypochlorite solution (chlorine bleach), can be added to the water reservoir 614 of the tank 214 through the spout 1414, without limitation. In some embodiments, the disinfectant fluid may contain a sodium hypochlorite solution at parts per 200 million, based on the tank size and the concentration of the active ingredient in the solution. The front insulation 208 can be replaced, and the control switch 4010 can be moved to the "on" position, at which point automatic confirmation can be performed again by one short beep followed by one long beep three seconds later. Next, the front panel assembly 122 of the ice maker 110 can be replaced. To avoid excessive foaming, there may be an automatic 1-minute delay between cycles. After the disinfectant solution has been automatically circulated in the water circuit 450 for about 30 minutes, the ice maker 110 can then automatically perform three consecutive rinse cycles. When the controller 232 starts beeping (again, in the form of the five-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 ice storage container 190 can then be cleaned with a neutral detergent and thoroughly rinsed. Subsequently, the mode switch 4012 can be switched back to the "ice" position, and then the control switch 4010 can be switched back to the "on" position to resume ice production.The front panel assembly 122 can then be reattached to the ice maker 110.

[0105] Figures 41 to 43 show flowcharts illustrating the operation of the controller 232 of the control box 230 regarding at least the cleaning and disinfecting functions of the overall cleaning procedure of the ice maker. The entire cycle across each flowchart described below may represent either a cleaning cycle or a disinfecting cycle. As shown in Figure 41, the overall operation flowchart 4100 may include steps 4110 and 4120 related to cleaning and disinfection. Step 4110 may include the controller 232 determining whether the mode switch 4012 is in the "cleaning" position. If the answer is no, step 4120 may include the controller 232 determining whether the cleaning step is rinsing. In addition, if the answer is no, the cleaning cycle is not started by the controller 232. If the answer to either step 4110 or step 4120 is yes, a cleaning cycle is started, beginning with the steps shown in the first cleaning flowchart 4200 (shown in Figure 42).

[0106] As shown in Figure 42, the first cleaning flowchart 4200 may include steps 4210 to 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 in the first cleaning flowchart 4200 may be omitted, 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 1 second. Step 4240 may include the controller 232 determining whether the cleaning process has started. If the answer is no, again, any subsequent steps in the first cleaning flowchart 4200 may be omitted, and the controller 232 may jump to the steps of the second cleaning flowchart 4300. If the answer is yes, then step 4250 may include circulating water within the water circuit 450 as illustrated in the flowchart or above. More specifically, step 4250 may include turning on the cleaning valve 354 (shown in Figure 3) and turning off the inlet valve 352 (shown in Figure 3) and the drain valve 356 (shown in Figure 3). Step 4260 may include draining water from the water reservoir 614 as illustrated in the flowchart or above. More specifically, step 4260 may include turning on the drain valve 356 and turning off the inlet valve 352 and the cleaning valve 354. Step 4270 may include filling the water reservoir 614 as illustrated in the flowchart or above. More specifically, step 4270 may include turning on the inlet 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 a solution. Step 4290 may include the controller 232 sounding two short beeps every 5 seconds as a signal for the user to proceed to the next step (pouring the cleaning fluid (in the case of a cleaning cycle) or pouring the disinfecting fluid (in the case of a disinfecting cycle).In fact, any subset or all of steps 4220-4290 can be automated up to the point where the user signals to pour the cleaning or disinfecting fluid, and including this signal, so that no user intervention is required. Subsequently, the first cleaning flowchart 4200 can proceed to the second cleaning flowchart 4300.

[0107] As shown in Figure 43, the second cleaning flowchart 4300 may include steps 4310-4390 that may follow the injection of the user's cleaning fluid. Step 4310 may include the controller 232 determining whether 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 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 pulsate or pulse the water pump, effectively using a rapid pressure tap to help more powerfully clean the surface of the water circuit 450 by removing limescale, calcium deposits, and other contaminants from the surface of the water circuit. Step 4350 may include the controller 232 draining water from the water reservoir 614. If the answer to step 4310 is no, the controller 232 can skip directly to steps 4340 and 4350 (i.e., the controller 232 can skip the rinsing step). Steps 4360-4380 may comprise a single rinsing cycle. More specifically, step 4360 may include the controller 232 filling the water circuit 450 with water reservoir 614, step 4370 may include the controller 232 circulating water through the water circuit 450 to the water pump, and step 4380 may include the controller 232 draining water from the water reservoir 614 to the water pump. Step 4390 may include the controller 232 repeating steps 4360-4380 until a third rinsing cycle is completed. Step 4392 may include the controller 232 resetting the cleaning process to start again (in preparation 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.Furthermore, any subset or all of steps 4310-4394 can be automated to eliminate the need for user intervention. The steps described above in the first cleaning flowchart 4200 and the second cleaning flowchart 4300 can be repeated to carry out a disinfection cycle.

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

[0109] Several advantages can be realized in the cleaning and disinfection processes described herein. Although some degree of manual intervention by the user may be required in some embodiments, as already shown, many steps that were manually timed and / or initiated in conventionally implemented processes are now automated. In the cleaning phase, for example, nine basic steps are reduced to five, and all time adjustment steps are incorporated into the controller 232 (as indicated by various beeping cues to the user). In the disinfection phase, the 14 basic steps following the cleaning phase are similarly reduced to five, and similarly, all time adjustment steps are incorporated into the controller 232 (as indicated by various beeping cues to the user). In conventionally implemented processes, the water pump hose had to be disconnected and reconnected multiple times between each stage, and the cleaning valve also had to be opened and closed multiple times between each stage, and continuous monitoring of the overall cleaning and disinfection process could take several hours. However, in the method described herein, the user can leave the area and return when prompted by beeping from the control panel, so continuous monitoring is not required even for a two-hour cleaning process. The complexity of the water circuit 450 is also significantly reduced. The more than 50 parts previously required now only about 22 parts, representing a reduction of over 50%. This is possible by replacing the conventional manual cleaning valve with valves 352, 354, and 356 as shown in Figure 2C, and by controlling valves 352, 354, and 356 with controller 232.

[0110] In particular, note that conditional statements such as "can," "could," "might," or "may," unless otherwise specified or understood within the context in which they are used, are generally intended to communicate that certain embodiments include certain features, elements, and / or processes, while other embodiments do not. Therefore, such conditional statements do not generally suggest that features, elements, and / or processes are required to some extent in one or more specific embodiments, or that one or more specific embodiments necessarily include logic, with or without user input or prompting, for determining whether these features, elements, and / or processes are included in or performed in any particular embodiment.

[0111] It should be emphasized that the embodiments described above are merely examples of implementations, provided for the clear understanding of the principles of this disclosure. As those skilled in the art will understand, any process description or block in the flowchart should be understood to represent a module, segment, or code containing one or more executable instructions for performing a particular logical function or step within the process, which may not include or perform any function, and may be performed in a manner deviating from the illustrated or described order, including substantially simultaneous or reversed orders depending on the functionality included. Many changes and modifications may be made to the embodiments described above without substantially departing from the spirit and principles of this disclosure. Furthermore, the scope of this disclosure is intended to encompass all combinations and subcombinations of all elements, features, and embodiments described above. All such modifications and modifications are included in this specification and within the scope of this disclosure, and all possible claims for individual embodiments or combinations of elements or steps are supported by this disclosure.

Claims

1. A method for using an ice maker placed on top of a storage container, The ice maker is housed in the evaporator case of the ice maker, and the ice maker is formed on the evaporator of the ice maker, To recover ice from the aforementioned evaporator, Perform a complete cleaning procedure on the ice maker. An ice maker usage method, including, The aforementioned ice maker, A front panel assembly is mounted on the front of the ice maker so as to be slidable vertically, The central part of the lower end of the front panel assembly is fastened to the ice maker. Equipped with, The overall cleaning procedure described above is: By loosening the fasteners, removing the front panel assembly, and accessing the switch of the ice maker, Activating the switch of the ice maker, The first manual intervention involves initiating the overall cleaning procedure, A first automated step includes sounding an audible alarm to warn the user that a second manual intervention is required, which involves pouring one of the cleaning fluid and the disinfecting fluid into the tank of the evaporator case, The second manual intervention includes pouring one of the cleaning fluid and the disinfecting fluid into the tank, A second automatic step includes automatically starting and completing at least one of the cleaning and disinfecting steps upon completion of the second manual intervention, and automatically starting at least one of the cleaning and disinfecting steps, which includes operating a cleaning valve in the water circuit of the ice maker by the main controller of the ice maker, A third automated step includes automatically starting and completing the rinsing stage. Includes, Here, The aforementioned ice maker, A spray tube positioned above the tank, A water pump is located outside the tank and connected to the bottom of the tank via a suction hose extending from the bottom of the tank to the outside of the tank, A heat-insulating pipe connected from the water pump to the spray tube, A supply tube inlet pipe is connected to a supply tube that has an inlet water valve and a supply tube portion located in the evaporator, A first pipe, which is attached to the lower part of the aforementioned insulated pipe and is equipped with a drain valve, A second pipe, equipped with a cleaning valve, connects the supply tube inlet pipe and the first pipe, An inlet water valve inlet pipe, which is connected to the supply tube inlet pipe via the inlet water valve and has a water inlet, The drain valve outlet pipe is connected to the first piping via the drain valve and to a drain equipped with a water outlet. It is further equipped with a water circuit, Here, The tank has a drain for discharging water, and the drain valve outlet pipe is connected to the drain outside the tank. How to use the ice maker.

2. Pouring one of the cleaning fluid and the disinfecting fluid into the tank includes pouring one of the cleaning fluid and the disinfecting fluid into a spout defined on the tank, the spout being inclined downward horizontally from the front end of the tank. The method according to claim 1, further comprising directing one of the cleaning fluid and the disinfecting fluid to a water reservoir defined by the tank.

3. The water pump of the ice maker is to pulsate at least one of the following: a) the cleaning fluid and the disinfecting fluid, and b) the water coming out of the water pump. a) to deliver at least one of the cleaning fluid and the disinfecting fluid and b) the water to the evaporator in a pulsating manner through the water circuit of the ice maker, thereby facilitating the cleaning of the evaporator. The method according to claim 1, further comprising:

4. The method according to claim 1, wherein the overall cleaning procedure is performed while all the piping of the water circuit remains connected.

5. In the first automatic step described above, The process involves opening the cleaning valve and closing the inlet water valve and the drain valve, and then operating the water pump to circulate the liquid in the water circuit. The process involves opening the drain valve and closing the cleaning valve and the inlet water valve, and then draining the liquid from the water circuit. After the step of draining the liquid from the water circuit, the inlet water valve is opened and the cleaning valve and the drain valve are closed, and an alarm is sounded to warn the user that a second manual intervention is required. The method according to claim 1, including the method described in claim 1.

6. Forming ice on the evaporator is The process involves spraying water downward into a series of channels defined by the evaporator plate of the evaporator, wherein the evaporator is positioned vertically within the evaporator case. To form ice cubes on the surface of the evaporator plate, Includes, Recovering ice from the evaporator includes releasing ice cubes from the surface of the evaporator plate during the recovery cycle of the ice maker. The method according to claim 1.

7. Activating the switch of the ice maker, which includes a first manual intervention that includes initiating an overall cleaning procedure, A first automated step includes sounding an audible alarm to warn the user that a second manual intervention is required, which involves pouring either a cleaning fluid or a disinfecting fluid into the tank of the evaporator case of the ice maker, The second manual intervention includes pouring one of the cleaning fluid and the disinfecting fluid into the tank, The second automatic step includes automatically starting and completing at least one of the cleaning and disinfecting stages upon completion of the second manual intervention, wherein automatically starting the cleaning and disinfecting stages includes operating a cleaning valve in the water circuit of the ice maker by the main controller of the ice maker, A third automated step includes automatically starting and completing the rinsing stage. Includes, The aforementioned ice maker, A spray tube positioned above the tank, A water pump is located outside the tank and connected to the bottom of the tank via a suction hose extending from the bottom of the tank to the outside of the tank, A heat-insulating pipe connected from the water pump to the spray tube, A supply tube inlet pipe is connected to a supply tube that has an inlet water valve and a supply tube portion located in the evaporator, A first pipe, which is attached to the lower part of the aforementioned insulated pipe and is equipped with a drain valve, A second pipe, equipped with a cleaning valve, connects the supply tube inlet pipe and the first pipe, An inlet water valve inlet pipe, which is connected to the supply tube inlet pipe via the inlet water valve and has a water inlet, The drain valve outlet pipe is connected to the first piping via the drain valve and to a drain equipped with a water outlet. It is equipped with a water circuit, Here, the tank has a drain for discharging water, and the drain valve outlet pipe is connected to the drain outside the tank. In the first automatic step described above, The process involves opening the cleaning valve and closing the inlet water valve and the drain valve, and then operating the water pump to circulate the liquid in the water circuit. The process involves opening the drain valve and closing the cleaning valve and the inlet water valve, and then draining the liquid from the water circuit. The process involves opening the inlet water valve, closing the cleaning valve and the drain valve, and sounding an alarm to warn the user that a second manual intervention is required. A method that includes this.

8. Pouring one of the cleaning fluid and the disinfecting fluid into the tank includes pouring one of the cleaning fluid and the disinfecting fluid into a spout defined on the tank, the spout being inclined downward horizontally from the front end of the tank. The method according to claim 7, further comprising directing one of the cleaning fluid and the disinfecting fluid to a water reservoir defined by the tank.

9. A fluid containing one of the cleaning fluid and the disinfecting fluid is sent to the evaporator of the ice maker through the water circuit of the ice maker, The water pump of the ice maker is configured to pulsate the fluid sent to the evaporator, To facilitate cleaning of the evaporator, the fluid is supplied to the evaporator in a pulsating state. The method according to claim 7, further comprising:

10. The method according to claim 7, further comprising circulating one of the cleaning fluid and the disinfecting fluid for a predetermined time.

11. The method according to claim 10, wherein the predetermined time is 30 minutes or less.

12. The method according to claim 7, wherein the overall cleaning procedure is performed while all the piping of the water circuit remains connected.

13. The aforementioned auditory alarm is a first auditory alarm, The method according to claim 7, further comprising sounding a second auditory alarm before or after sounding the first auditory alarm.

14. The method according to claim 7, further comprising injecting one of the cleaning fluid and the disinfecting fluid into the tank, and then starting a delay timer.

15. The method according to claim 7, wherein automatically starting and completing at least one of the cleaning step and the disinfection step includes starting the cleaning step.

16. The method according to claim 7, wherein automatically starting and completing the rinsing step includes starting and completing a plurality of rinsing cycles.

17. The method according to claim 7, further comprising maintaining a pH level of 7 ± 0.5 in the water within the water circuit after the completion of the overall cleaning procedure.

18. The method according to claim 15, further comprising initiating a disinfection step.

19. The method according to claim 9, wherein delivering the fluid to the evaporator in a pulsating state to facilitate cleaning of the evaporator includes delivering the fluid to the evaporator in a pulsating state for at least 3 minutes.

Images