CN110073155B

CN110073155B - Dry-type collection ice maker

Info

Publication number: CN110073155B
Application number: CN201780059529.2A
Authority: CN
Inventors: E·莫尔
Original assignee: Icebow Ltd
Current assignee: Icebow Ltd
Priority date: 2016-08-10
Filing date: 2017-08-09
Publication date: 2021-11-09
Anticipated expiration: 2037-08-09
Also published as: CN110073155A; WO2018029687A1

Abstract

An ice maker includes a pressure source configured to provide a gas at a pressure above ambient pressure. The ice-making machine includes an evaporator grid including an evaporator back plate and a resilient substrate disposed above the evaporator back plate, the resilient substrate configured to resiliently contract in thickness toward the evaporator back plate. The evaporator grid includes a gas valve in fluid communication with a pressure source. The ice-making machine includes one or more controllers configured to induce separation between the resilient base and an ice plug formed in the evaporator grid. The gas valve is configured to inject a gas into a space formed by the separation, wherein the gas has a pressure higher than ambient pressure.

Description

Dry-type collection ice maker

Cross Reference to Related Applications

The present application claims priority from U.S. provisional patent application No.62/372817 entitled "Dry Harvesting for Ice Cube Makers" filed on 8, 10, 2016, U.S. provisional patent application No.62/446,902 entitled "Dry Harvesting components for Ice Makers" filed on 1, 17, 2017, and U.S. provisional patent application No.62/504,157 entitled "Ice Supporting Plate for Dry Harvesting Ice maker" filed on 5, 10, 2017, which is incorporated herein by reference in its entirety.

Technical Field

The present invention relates to the field of ice making machines.

Background

The ice maker can make ice in different forms such as blocks, tubes, plates, sheets, and/or the like. Many machines operate batch-wise and use wet ejection to remove ice after it has formed on the evaporating surface. During wet ejection/ejection (ejection), it is possible to heat the evaporation surface by using a refrigeration element operating in reverse, and the ice near the surface melts to release ice bricks, ice slabs, a batch of ice, ice tubes, and/or the like. The ejected ice drops into a collection bin and the ice tube machine cuts the long ice tube into small pieces. Ice cube makers may typically be used in restaurants, hotels and/or the like, while ice cube makers and ice board makers may be used for commercial ice production, such as ice bags dispensed to supermarket chains, ice for fisheries and/or the like.

The foregoing examples of related art and limitations related thereto are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.

Disclosure of Invention

The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools, and methods, which are meant to be exemplary and illustrative, not limiting in scope.

According to one embodiment, an ice making machine is provided that includes a pressure source configured to provide a gas at a pressure above ambient pressure and an evaporator grid. The evaporator grid includes an evaporator back-plate (e.g., the evaporator back-plate can be made of a highly conductive polymer, a combination of metal and polymer, metal, etc.) and a resilient substrate disposed over the evaporator back-plate, the resilient substrate configured to resiliently contract in thickness toward the evaporator back-plate by at least 10 microns. The evaporator grid includes a gas valve in fluid communication with a pressure source. The gas valve is configured to initiate separation between the resilient base and an ice plug formed in the evaporator grid. The ice maker includes one or more controllers configured to inject gas into a space formed by the separation, wherein the gas has a pressure above ambient pressure.

In some embodiments, the evaporator grid further comprises an ice sealing mechanism along a perimeter of the evaporator back plate, wherein the ice sealing mechanism is configured to prevent gas from escaping until the ice is mostly separated from the resilient substrate, and is configured for later bouncing the ice into the dispenser.

In some embodiments, the ice sealing mechanism includes one or more of: an angled metal surface, wherein the angled metal surface is substantially rigid; a groove; a rigid region of the resilient substrate; a heating element; a mechanical control lever; a compressible pad disposed within the groove; and a removable sealing frame.

In some embodiments, the gas valve comprises a gas outlet recess and one or more of: an inflatable cushion in mechanical communication with the gas outlet recess; a center pin configured to seal the gas outlet recess when ice forms in the evaporator grid; a piston connected to one edge of the gas outlet recess and configured to slide away from the gas outlet recess when gas is applied; and a central pin configured to slide out of the gas valve towards the ice plug and to help eject the ice plug.

In some embodiments, the evaporator back plate includes a plurality of voids for receiving at least a portion of the resilient substrate when the resilient substrate elastically contracts.

In some embodiments, the resilient substrate includes a plurality of flexible regions, one or more flexible regions along each corner of the resilient substrate.

In some embodiments, the ice plug comprises a plurality of ice pieces and the ice maker is an ice cube maker.

In some embodiments, the ice plug comprises one or more ice tubes, the evaporator grid is an array of evaporator tubes, and the ice maker is an ice tube machine.

In some embodiments, the ice plug comprises one or more ice sheets, and the ice maker is a plate ice maker.

In some embodiments, the gas is at an ambient pressure that is at least 0.1 bar above ambient pressure.

In some embodiments, the gas is at ambient pressure and the evaporator grid is maintained at a pressure at least 0.1 bar below ambient pressure using a fluid connection with a suction pump.

In some embodiments, the ice maker further comprises a rigid ice support plate opposite the resilient base plate for preventing the ice cube from bending during ejection.

In some embodiments, the rigid ice support plate includes raised ridges.

In some embodiments, the ice maker further comprises a splash plate, and wherein the rigid ice support plate is incorporated into the splash plate.

In some embodiments, the ice maker comprises a splash plate, and wherein the rigid ice support plate is connected to the splash plate.

According to one embodiment, there is provided a method for ejecting ice from an ice maker, comprising using one or more controllers configured for commanding the act of introducing gas into a gas valve of an evaporator back plate connected to an evaporator grid, wherein the gas is at a pressure at least 0.1 bar above ambient pressure. The controller(s) is configured to initiate an action of separation between the ice cake and a resilient base plate disposed over the evaporator backplate in an area around the gas valve by mechanically manipulating an outlet recess of the gas valve. The controller(s) is configured for the act of expanding the separation between the ice nuggets and the resilient base by contracting the resilient base at least 10 microns toward the evaporator backplate until a majority of the ice nuggets separate from the resilient base.

In some embodiments, the method further comprises the act of applying a force at least partially towards the resilient base during the separation of the ice lumps, and further comprises the act of releasing the force during the ejection of the ice lumps.

In some embodiments, the method further comprises the act of ejecting the ice plug from the evaporator grid by: the seal between the ice plug and the evaporator grid around the periphery of the resilient base plate is broken and an ejection force is exerted on the ice plug in the direction of the ice dispenser.

In some embodiments, the seal is created during formation of an ice lump on an angled metal surface, wherein the angled metal surface is substantially rigid.

In some embodiments, the seal is created during formation of an ice lump in the recess.

In some embodiments, the breaking of the seal comprises one or more of the following actions: activating the heating element; operating a mechanical control lever; expanding a compressible pad disposed within the groove; and moving the removable sealing frame.

In some embodiments, the ejecting force is applied by the action of sliding the central pin out of the gas valve towards the ice plug to help eject the ice plug.

In some embodiments, initiating/initiating separation includes the act of releasing gas from the outlet notch and one or more acts from the following acts: inflating a valve gasket in mechanical communication with the gas outlet notch; moving a center pin configured to seal the gas outlet recess when ice is formed in the evaporator grid; a piston slidably connected to one edge of the gas outlet recess in a direction away from the gas outlet recess when gas is applied; heating ice around the valve; low pressure gas is leaked into the water before ice formation.

In some embodiments, the contraction of the resilient substrate facilitates compression of at least a portion of the resilient substrate into the plurality of voids in the evaporator back plate.

In some embodiments, the gas passes through corners in the resilient substrate at a plurality of flexible regions, one or more flexible regions along each corner of the resilient substrate.

In some embodiments, the pressure of the gas is at least 0.1 bar above ambient pressure.

In some embodiments, the elastic substrate has a shrinkage of at least 10 microns towards the evaporator back plate.

In some embodiments, the contraction of the resilient base towards the evaporator backplate continues until a majority of the ice mound separates from the resilient base.

In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed description.

Drawings

Exemplary embodiments are illustrated in referenced figures. The dimensions of the components and features shown in the figures are generally selected for convenience and clarity of presentation and are not necessarily shown to scale. These figures are listed below.

FIG. 1 shows a schematic diagram of an ice making machine with dry harvest;

FIG. 2 shows a flow chart of a method for dry harvesting of ice;

FIG. 3 shows a schematic view of an evaporator grid for dry harvesting of ice;

FIG. 4 shows a cross-sectional view of an evaporator grid for dry harvesting of ice;

FIG. 5 shows a cross-sectional view of a compression gas valve for dry harvesting of ice;

FIG. 6 shows a cross-sectional view of a compressed air valve measurement for dry harvesting of ice;

FIG. 7 shows a cross-sectional view of a compression gas valve for dry harvesting of ice during a separation stage;

FIG. 8 shows a cross-sectional view of a bubble generated by a valve for dry harvesting of ice;

FIG. 9 shows a cross-sectional view of bubbles generated by a second valve for dry harvesting of ice;

FIG. 10 shows a cross-sectional view of grid voids for dry harvesting of ice;

FIG. 11 shows a cross-sectional view of a flexible region of an elastic substrate for dry harvesting of ice;

FIG. 12 shows a cross-sectional view of an ice plate seal for dry harvesting of ice;

FIG. 13 shows a cross-sectional view of a separated ice plate seal for dry harvesting of ice;

FIG. 14 shows a cross-sectional view of a mechanically separated ice plate seal for dry harvesting of ice;

FIG. 15 shows a cross-sectional view of a pressure activated ice plate seal for dry harvesting of ice;

FIG. 16 shows a cross-sectional view of a valve with a pop-pin for dry harvest of ice;

FIG. 17 illustrates a cross-sectional view of an ice pipe machine with dry harvesting of ice;

FIG. 18 illustrates a transverse cross-sectional view of an icetube machine with dry harvest for ice;

FIG. 19 shows a transverse cross-sectional view of ice tubes separated from an evaporator grid during dry harvesting of ice;

FIG. 20 shows a transverse cross-sectional view of ice tubes ejected from an evaporator grid during dry harvest of ice;

FIG. 21 shows a cross-sectional view of an alternative ice tube ejection during dry harvesting of ice;

fig. 22 shows a schematic view of an embodiment of a dry pop-up with splash curtain.

Fig. 23 shows a schematic view of an embodiment of a dry pop-up with a splatter curtain before ice formation.

Fig. 24 shows a schematic view of an embodiment of dry pop-up with a splatter curtain after ice formation.

Fig. 25 shows a schematic view of an embodiment of a dry pop-up with a splatter curtain during ice pop-up.

Fig. 26 shows a schematic view of an embodiment of a dry pop-up with a splatter curtain after ice pop-up.

Detailed Description

Methods and apparatus for dry ejecting ice bumps, bricks, tubes, and/or the like in an ice making machine are described herein. Dry ejection of ice lumps can be performed using a valve configured to inject a compressed fluid between the ice and an evaporator grid, wherein the evaporator grid comprises a back plate (i.e. having a high thermal conductivity) and a resilient substrate. The fluid may be an ambient gas, such as air, treated gas, liquid (e.g., water), and/or the like, and the term gas and/or air as used herein may refer to any fluid suitable and/or capable of separating between the ice sheet and the grid. For example, the gas has a density lower than ambient atmosphere. The valve may also be configured to be at least partially flexible and/or resilient, and to initiate a crack between the ice and the grid when compressed gas is applied to the valve. The grid may be covered with one or more resilient substrate materials that may allow the substrate to move away from the ice by the movement of compressed gas, e.g., thickness shrinkage. Special flexible zones are provided around the corners so that compressed gas passes most of the way between the ice and the grid.

A special area around the periphery of the ice grid can form a seal for retaining compressed gas between the ice and the grid without leaking from the edges of the grid. For example, the ice gasket groove is filled with water, which freezes into ice, thereby forming a seal. Once the ice and the grid are mostly separated, the ice is ejected by releasing the seal around the perimeter of the ice. These stages of dry ejection may be referred to as separation initiation, ice detachment, and ice ejection. Dry ejection may be used with ice cube makers, ice tube makers, ice plate makers, and/or the like having horizontal or vertical evaporators.

As used herein, the term "valve" refers to an orifice in the evaporator grid for injecting compressed air between the grid and one or more ice lumps formed on the grid. The valve may be a simple hole, a slit, a hole with some flexible means to initiate separation between the ice plug(s) and the grid, a hole with a mechanical element to facilitate ejection of the separated ice, and/or the like. The valve may operate at a positive or negative pressure relative to ambient pressure. For example, the valve may have a slit that prevents water from entering the valve and forming ice. The flexible region of the valve at least partially surrounding the slit will be deformed by the application of compressed gas within the valve such that at least some of the flexible region will separate from the ice plug and allow compressed gas to pass between the ice plug and the resilient base plate. Optionally, flexible regions and/or components within the valve may facilitate initial separation of ice from the resilient substrate.

In order for the grid to have a resilient base while maintaining good thermal conductivity to form ice, the grid may comprise two or more different materials, e.g. (i) a base with good thermal conductivityA material, and (ii) an ice-forming substrate. The base material of the grid may be a high thermal conductivity material, for example between 2 and 400 watt-meters per kelvin (Wm/k), which may be very hard, for example a metal alloy comprising copper, zinc, aluminum and/or the like. An elastic heat conductive substrate made of a flexible heat conductive material covers a base material, such as an evaporator back plate, to form ice on the elastic substrate. For example, the elastic substrate has a Shore hardness (OO scale) with a value of 10 to 90, such as a gel material, a paste, a rubber material, a synthetic viscoelastic polyurethane polymer

Materials and/or the like, and may also be composed of multiple materials having different shore hardnesses. An example of a resilient substrate is a Thermal Interface Material (TIM) consisting of a polymerizable matrix and a large volume fraction of thermally conductive filler. Typical matrix materials are epoxies, silicones, polyurethanes and acrylates, solvent based systems, hot melt adhesives and/or the like. Alumina, boron nitride, zinc oxide, aluminum nitride and/or the like are used as fillers for these types of materials.

Between the substrate and the grid, a series of voids may be filled with gas and/or air and positioned on the grid such that a resilient substrate (which may be a non-compressible material) may expand into the voids as compressed gas passes between the ice and the substrate. Thus, the thickness of the elastic substrate may be shrunk by at least 10 micrometers, thereby separating from the ice. For example, the elastic material shrinks between 5 microns and 5 millimeters. Optionally, the resilient substrate comprises gas voids, such as bubbles, microbubbles and/or the like, which contract during the passage of the compressed gas and allow for resilient flexibility of the substrate. The resilient thermally conductive substrate may also include a thin outer layer of a highly deflected, hard (stiff), flexible material, such as a food safe metal, on the side where the ice mound is formed to provide mechanical support for the flexible substrate. The hard outer layer may help:

when the gas pressure is removed, the elastic heat-conductive substrate is restored to the original size and shape,

the durability of the grid is such that,

food and Drug Administration (FDA) compliance,

the degree of hydrophobicity,

the degree of hydrophilicity,

and/or the like.

For example, hard steel, hard stainless steel, spring steel, metal alloys including phosphor bronze, nickel, cobalt, brass, and/or the like may be used as the hard outer layer of the resilient substrate.

The outer layer may consist of a specific coating of food-safe material with a "hydrophobic texture" or a "hydrophilic texture", for example consisting of elements of "millimetre" (mm), micrometre (mum) or submicrometre dimensions, which elements may be periodic, quasi-periodic or disordered. For example, the geometry may consist of a post, a cone, a sphere, a series of geometries, a combination of shapes, a protrusion, a niche, and/or the like. The texture may be produced using a combination of thermal embossing techniques, etching processes, layer-by-layer deposition, and/or the like. These textures may serve as micro air channels during movement of the compressed gas.

The resilient base may be attached to the grid and/or evaporator by gluing, adhesives, compression springs, compression bolts, rivets, compression rivets, springs, spot welding, ultrasonic welding, cold welding and/or the like. The outer layer may be manufactured and/or attached, in whole or in part, to the resilient base by stamping, folding, pressing, grinding, deep drawing, over-molding with a polymer, and/or the like.

The initial stage of separation is the formation of cracks between the ice surrounding the valve and the grid, and the valve may play a passive role in crack formation (e.g. initial separation between ice and substrate). The stage of ice detachment is facilitated by an elastic substrate, which is sufficiently flexible to be displaced, for example several to tens of microns away from the ice, with voids allowing such displacement. For example, the resilient substrate is between 5 microns and 4 millimeters thick, and the substrate is displaced from ice by 3 microns to 500 microns. The thin flexible substrate may allow for the use of materials having relatively high thermal conductivity (e.g., 17 Wm/K).

The ice ejection phase is facilitated by releasing the seal around the ice. The seal may also assist in ice detachment by keeping the pressure between the ice and the substrate high (e.g., relative to ambient pressure), such that the ice is completely detached before being ejected. There are several embodiments of the valve in separating the initial functions. There are several embodiments of the function of the base plate and seal in ice detachment. There are several embodiments of the function of the seal in ice ejection. Each of these embodiments also includes modifications to the valve, base plate, and seal, and thus these three aspects may be implemented differently in various embodiments, where the functions may be similar.

Optionally, the edges and/or corners of the grid in the ice cube machine include more flexible regions to allow the resilient heat conducting substrate to pass compressed gas around the corners. For example, each edge of the substrate defining a corner between two faces of the ice cube and/or grid has a slightly thicker region of the substrate, a local void, and/or the like to provide some additional flexibility to the rest of the resilient substrate. For example, the metal layer covering the flexible material has holes, slits and/or the like. Optionally, the ice cube maker has a grid with draft angles in each cube of the grid to facilitate ejecting ice lumps, such as a connected slab of ice cubes.

Optionally, the compressed gas is compressed air. For example, the compressed gas may be air, CO₂Gas and/or the like.

Optionally, the compressed gas is at ambient pressure and the pressure in and around the evaporator grid is below ambient pressure. For example, a suction pump is applied to the evaporator grid and the surrounding area of the ice maker, thereby reducing the pressure in the void to at least 0.1 bar below ambient pressure, and the compressed gas entering the valve is ambient pressure gas, e.g., high pressure gas. The term high pressure gas refers to a gas at a pressure higher than the void pressure in the evaporator grid. For example, when the interspace is in fluid connection with a suction pump, the interspace may have a pressure of 0.1 bar below ambient pressure and a pressure of up to 5 bar below ambient pressure.

Optionally, the grid voids are at least partially interconnected. For example, two or more voids are connected by a channel that allows for converting pressure at one point (e.g., a first void) between the ice and the grid to mechanical force at a second point (e.g., a second void) between the ice and the grid. Such interconnection may facilitate the propagation of compressed gas by further applying mechanical forces to the ice and the areas where the grid is still firmly attached. For example, the interconnecting channels allow to convert the pressure at the first void into a shear stress of the resilient substrate at another location along the grid.

Optionally, the valve includes a pin to promote crack initiation or ice ejection. For example, the pin extends above the gas valve, for example mushroom shaped, so that no ice is formed on the gas outlet of the valve. For example, the pin is configured to move in the direction of the ice to force the ice to pop out of the grid.

For example, compressed gas at a pressure of 0.3 bar above (or below in the case of a negative pressure embodiment) ambient/Atmospheric Pressure (AP) is introduced into the valve (e.g., 4.35 pounds per square inch above AP) and the flexible wall of the valve expands outward from the center of the valve causing the gas outlet to peel away from the adjacent ice pieces of the filling grid. This may allow compressed gas to pass between the ice and the grid on the first side of the ice and to the edge of the first side. When the compressed gas reaches the flexible zone along the edge, the compressed gas passes the corner to the lower side of the ice cube. Similarly, the compressed gas passes through the top of the grid to the next ice cube, and thereby releases all ice cubes from the grid. Now, a seal around the grate holds the ice cube tray to the grate, and ice cube trays (as in a batch) are ejected from the grate by releasing the seal, e.g., moving a mechanical element, increasing the pressure (or decreasing in the case of a negative pressure embodiment) to an ejection pressure value (e.g., 0.5 bar above AP), operating a heating element, and/or the like. Optionally, the heating element adjacent the ice seal is progressively heated until the ice forming the seal melts and the ice is ejected. Optionally, the seal is heated and the pressure is gradually increased (or decreased in the case of a negative pressure embodiment) until the ice is ejected. Optionally, hot, chilled gas is used to heat the seal.

Optionally, a portion of the seal or any other portion from the ice plug remains on the grid to promote nucleation of ice ejected onto the grid at the beginning of the next freezing process, thereby reducing water subcooling temperature and energy loss.

The compressed gas partially passes between the ice and the grid because of the pressure difference between the gas in the void and the gas in the valve. Once this pressure difference exceeds a value such as 0.3 bar, the crack germinates and propagates until the ice breaks away from the grid. This can be done by injecting compressed gas into the valve, or by depressurizing the void and the gas surrounding the valve. For example, the compressed gas is at a pressure of 0.35 bar above ambient pressure (or below in the case of a negative pressure embodiment). For example, the gas pressure in the gap and around the valve is 0.3 bar lower than AP, e.g. negative pressure.

Optionally, the seal is heated to melt the ice forming the seal, thereby ejecting the ice sheet.

Optionally, some gas pressure is applied during the formation of the ice cubes to prevent ice from forming directly on the valve gas outlet holes.

In wet ice ejection, the grid is heated until the ice sheet or tube falls off the grid, optionally shredded, and enters the dispenser. This heating is both time consuming and requires energy to force the heat back into the grid to eject the ice. By ejecting ice dry, the ejection time can be shortened relative to wet ejection, and energy for heating the grid can be saved. Thus, the benefits of dry ejection in ice makers are significant. The aspects described herein have the benefit of not requiring moving parts when separating between ice and the grid, and are therefore robust and easy to maintain. Aspects described herein can separate two or more sides of an ice cube (e.g., up to all 5 sides of a brick-shaped ice cube). Other configurations of ice cube shapes can benefit from aspects described herein, such as various faces of an ice "cube" having different cross-sectional shapes, e.g., star shaped ice cubes, heart shaped ice cubes, as produced in a Hoshizaki ice maker, and so forth. For example, the resilient base and valve can be connected to any evaporator grid and can be incorporated into an existing ice making machine with only a few simple changes to the machine. Since the amount of air required to separate the ice is small, for example up to 100 cl, the air pump required to be added to the existing machine is small and may be pre-pressurized prior to ejection.

Following is an ice maker (e.g., using dry eject) according to aspects described herein

Model ICE0605FA-5 ICE maker), where the units: kilowatt (KW) and KW hour (KWh):

TABLE 1

The following is a table of the operational benefits of a household refrigerator Ice Maker wherein the Ice Mold has 8 Ice cube molds, each 17.5 milliliters (cc) (e.g., Whirlpool Kenmore Ice Machine Ice Maker Mold and Heater W10190929) each)

TABLE 2

The following is an example illustration of aspects of certain embodiments.

Referring now to FIG. 1, a schematic diagram of an ice making machine 100 with dry harvest is shown. Ice maker 100 includes a water source 105, the water source 105 being configured to flow water over an evaporator grid 101 (e.g., an ice cube grid, an ice slab grid, an ice duct grid, and/or the like). The term grid refers to a thermally conductive surface, such as an evaporator back plate, on which ice is formed by flowing water on one side and thermally connecting a refrigerant to the grid to remove heat from the water and form ice. A water trap 106 collects water that does not freeze on the grid 101 and the water is returned to the source 105. The source 105 is also connected to an external water supply. The refrigerator 107 is thermally connected to the grid and removes heat from the water to form ice. Once the ice slab, ice tube or the like is formed, the gas compressor 109 supplies compressed gas to the gas valve 104, which gas valve 104 initiates separation of the ice from the resilient substrate 103 of the grid. As used herein, the term "batch" refers to a quantity of ice formed on a grid, such as a plate, a tube, a series of connected ice cubes, and/or the like. Once the batch of ice separates from the substrate, the seal 102 is activated to release the batch of ice from the grid 101 and the batch of ice falls into the ice dispenser 108. The control operations of the water source 105, the refrigerator 107, the seal 102 and the gas compressor 109 are performed by one or more electronic controllers 110 based on sensors connected to the grid 101 and the water collector 106. Optionally, electronic controller 110 is a computer controller. Optionally, the water used to fill sump 106 flows at least partially along one side of the evaporator during dry harvest, thereby cooling the fresh water and further improving ice machine efficiency.

For example, the at least one controller is an embedded controller, a computer device, a computer, a server, and/or the like. A controller is configured by firmware, hardware, software, and the like to control, command, monitor, execute, and/or the like. Software, such as program code, may be configured in modules and stored on a non-transitory storage medium accessible to the controller. The computer program product may include a computer-readable storage medium (or media) having computer-readable program instructions thereon for causing a processor to perform various aspects of the invention.

The computer readable storage medium may be a tangible device that can retain and store instructions for use by an instruction execution device. The computer readable storage medium may be, for example, but is not limited to, an electronic memory device, a magnetic memory device, an optical memory device, an electromagnetic memory device, a semiconductor memory device, or any suitable combination of the foregoing. A non-exhaustive list of more specific examples of the computer-readable storage medium includes the following: a portable computer diskette, a hard disk, a Random Access Memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or flash memory), a Static Random Access Memory (SRAM), a portable compact disc read-only memory (CD-ROM), a Digital Versatile Disc (DVD), a memory stick, a floppy disk, a mechanical coding device (e.g., a raised structure in a punch card or groove having instructions recorded thereon), and any suitable combination of the foregoing. The computer-readable storage medium used herein should not be interpreted as a transitory signal per se, such as a radio wave or other freely propagating electromagnetic wave, an electromagnetic wave propagating through a waveguide or other transmission medium (e.g., optical pulses through a fiber optic cable), or an electrical signal transmitted through an electrical wire. In contrast, computer-readable storage media are non-transitory (also "non-volatile").

The computer-readable program instructions described herein may be downloaded from a computer-readable storage medium to a corresponding computing/processing device or to an external computer or external storage device via a network (e.g., the internet, a local area network, a wide area network, and/or a wireless network). The network may include copper transmission cables, optical transmission fibers, wireless transmissions, routers, firewalls, switches, internetworking computers and/or edge servers. The network adapter card or network interface in each computing/processing device receives computer-readable program instructions from the network and forwards the computer-readable program instructions for storage in a computer-readable storage medium within the respective computing/processing device.

Computer-readable program instructions for carrying out operations of the present invention may be assembler instructions, Instruction Set Architecture (ISA) instructions, machine-related instructions, microcode, firmware instructions, state setting data, or source or object code written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C + + or the like and conventional procedure oriented programming languages, such as the "C" programming language or similar programming languages. The computer-readable program instructions may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a Local Area Network (LAN) or a Wide Area Network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet service provider). In some embodiments, an electronic circuit comprising, for example, a programmable logic circuit, a Field Programmable Gate Array (FPGA), or a Programmable Logic Array (PLA), may personalize the electronic circuit by executing computer-readable program instructions with state information of the computer-readable program instructions in order to perform aspects of the present invention.

Aspects of the present invention are described herein with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer-readable program instructions.

These computer-readable program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the execution of the instructions by the processor of the computer or other programmable data processing apparatus create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. These computer-readable program instructions may also be stored in a computer-readable storage medium that can direct a computer, programmable data processing apparatus, and/or other devices to function in a particular manner, such that the computer-readable storage medium having the instructions stored therein comprise an article of manufacture including instructions which implement aspects of the function/act specified in the flowchart and/or block diagram block or blocks.

The computer readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer, other programmable apparatus or other devices implement the functions/acts specified in the flowchart and/or block diagram block or blocks.

Referring now to FIG. 2, a flow chart 200 of a method for dry harvesting of ice is shown. When the batch starts, the water cycle starts 201 and the refrigerator starts 202. When the ice is ready 203, the water circuit is stopped 204A and the gas is compressed 204. The compressed gas induces 205 separation of the ice from the substrate surrounding the valve and the separation propagates 206 throughout the evaporator grid through the compressed gas and the resilient substrate. An ohmmeter sensor may be connected between the elastomeric substrate 103 and the seal 102 to measure electrical resistance during the separation propagation 206 (e.g., when the gas 109 is insulated from ice). When the ice has not separated 207, the gas pressure and grid temperature are gradually increased 208 until the ice separates from the substrate. When the ice is separated, batches of ice are ejected 209, such as by operation of the seal, increasing (or decreasing in the case of a negative pressure embodiment) gas pressure, operating the seal heater, and/or the like. Optionally, the gas pressure is reduced to eject the batch of ice.

Referring now to fig. 3, a schematic diagram of an evaporator grid 300 for dry harvesting of ice is shown. The grid 300 has an array of ice cubes forming a recess 301 and a groove 302 for forming a seal.

Referring now to fig. 4, a cross-sectional view of an evaporator grid 401 for dry harvesting of ice is shown. The grate 401 includes a refrigerator heat exchanger 402 for extracting heat from the water to form ice cubes in the grate 401, such as by using an evaporator back plate. When the ice is fully formed, the gas valve 404 initiates separation of the ice from the grid 401 and passes compressed gas between the ice and the substrate 405. Once the ice separates from the substrate 405, the seal 406A or 406B is broken to eject the ice from the grid.

Referring now to fig. 5, a cross-sectional view of a compression gas valve 500 for dry harvesting of ice is shown. Compressed gas enters the valve at an orifice 501, the orifice 501 being surrounded by a valve gasket 502 mechanically connected to an outlet recess 505. In some embodiments, the pin 504 covers the outlet of the valve to prevent water from entering the valve 500. The valve pad pressure relief vent 503 allows the pad to expand, thereby initiating separation of ice 507 from the base plate 506.

Referring now to FIG. 6, a cross-sectional view of a compressed air valve measurement for dry harvesting of ice is shown. The pad outlet diameter is denoted as a and the pad wall thickness is denoted as c. The pin diameter is denoted by b and the pin length by z. The substrate may include a first layer having a thickness denoted x and a second layer having a thickness denoted y. The length of the inner valve portion may be denoted as q and the length of the inflatable cushion portion may be denoted as r. For example, a range of values for the valve size (in millimeters (mm)) is given in the following table:

TABLE 3

Referring now to fig. 7, a cross-sectional view of the

compression gas valves

700 and 702 is shown for dry harvesting of ice during the separation stage. Valve 700 shows a pad 701 that expands to initiate separation between ice and a substrate. Valve 702 shows the pad inflated without a pin to open notch 703 in gas valve 702. For example, when the pad 708 inflates, the notch opens. This allows compressed gas to pass 706 between the ice and the

substrates

704 and 705 after first exiting the valve through the recess (e.g., 707 between the valve and the ice).

Referring now to fig. 8, a cross-sectional view of a bubble 801 produced by a valve for dry harvest of ice is shown. In this embodiment, gas in valve 804 slowly leaks through the recess during ice formation, and after ice formation, bubbles 801 cover the outlet. The bubbles reach the

resilient substrates

802 and 805 and the grid 803 so that when compressed gas is applied to the valve, separation is induced by the pressure P on the

resilient substrates

802 and 805.

Referring now to fig. 9, a cross-sectional view of a bubble 904 for dry harvesting of ice produced by a second valve 901 is shown. Multiple capillaries in valve 901 can allow gas to leak into the water during ice formation, creating bubbles 904. When ice separation is initiated, the passage of compressed gas between the ice and the substrate 903 moves the substrate against the grid 902, resulting in the initiation of separation, such as the formation of cracks 905. Optionally, bubbles on the valve are generated by heating the ice around the valve using a heating element 907, wherein the heating element 907 is inserted into the valve and configured to discharge the melted ice water. After the bubbles are formed, the ice water discharge holes may be blocked with plugs 908. Referring now to FIG. 10, a cross-sectional view of a grid void 1004 for dry harvesting of ice is shown. The grid voids 1004 in the grid 1001 facilitate the separation of the substrate 1002 from the ice 1003 by providing space for the compressed gas 1005 to pass through the resulting displacement of the resilient substrate.

Referring now to fig. 11, a cross-sectional view of

flexible regions

1101 and 1102 of an elastomeric substrate 1103 used for dry harvesting of ice is shown. Since the resilient base is compressible only in the grid direction, the corners of the resilient base reduce the degree of deflection and act as contours and prevent movement of the base in all three directions. Thus, the corners of the substrate may become rigid. To allow separation of the substrate from the ice to continue around the corners, the substrate may include regions where the resilient substrate is more flexible, such as 1101 and 1102. For example, the first flexible region 1101 may include an elongated void surrounding a corner between the substrate and the grid. For example, the second flexible region 1102 may include an increased thickness of elastomeric material around the corner.

Referring now to FIG. 12, a cross-sectional view of an ice plate seal 1206 for dry harvesting of ice is shown. The seal 1206 is created by a sloped area extending around the ice sheet 1205, where the

resilient substrates

1202 and 1203 do not extend to the sloped area. This region prevents compressed gas 1204 from escaping between the

substrates

1202 and 1203 and the ice 1205 and thereby holds the ice 1205 within the grid 1201.

Referring now to FIG. 13, a cross-sectional view of a separated ice plate seal 1306 for dry harvest of ice is shown. As the pressure increases (or decreases in the case of a negative pressure embodiment), the seal is heated, the seal is mechanically moved, and/or the like, the ice plate 1305 will exit the grid 1301.

Referring now to fig. 14, a cross-sectional view of a mechanically separated ice plate seal 1403 for dry harvesting of ice is shown. When the ice sheet 1402 is detached from the grid 1401, a mechanical lever 1404 may move the ice sheet 1402 away from the grid 1401 by pushing the seal 1403 away from the grid 1401. This mechanism provides the further benefit of building a new ice sheet while the ice sheet 1402 is transferred to the dispenser.

Referring now to FIG. 15, a cross-sectional view of a pressure activated ice plate seal 1504 for dry harvesting of ice is shown. When the ice sheet 1502 is separated from the grid 1501, the pressure activated ice sheet seal 1504 within the sealed rigid housing 1503 may be activated by receiving compressed gas which causes the ice sheet seal 1504 to expand or contract and mechanically break the seal retaining ice sheet 1502 in the grid 1501 and release the ice to the dispenser.

Referring now to FIG. 16, a cross-sectional view of a valve 1601 for dry harvest of ice is shown, the valve 1601 having a pop-pin 1603. The pad 1602 is activated by the gas pressure in the valve 1601, separating the ice sheet 1604 from the grid. After separation, the plate 1604 is mechanically pushed out of the grid by pop-pins 1603, thereby popping up the ice sheet.

Optionally, when the grid is inverted and water is sprayed from below, plate ice is produced. Optionally, plate ice is produced when the grid is oriented at an angle and water is sprayed towards the grid.

Optionally, the ice pipe machine uses a dry eject embodiment as described herein.

Referring now to FIG. 17, a cross-sectional view of an ice pipe machine 1701 having a dry harvest for ice is shown. The ice pipe machine 1701 includes two or more tubes 1702 within the cabinet for distributing refrigerant. Each tube serves as a grid for forming ice tubes 1703 and includes a resilient substrate 1705 for separating the ice tubes 1703. The ice tube 1703 is ejected and the shredder 1704 cuts the elongated piece of ice into a shorter ice tube.

Referring now to FIG. 18, a transverse cross-sectional view of an icetube machine with dry harvest for ice is shown. Each evaporator grid (e.g., ice tubes 1801) has an internally covered resilient substrate 1802 and two or more pop-up seals 1803, where the tube base material may serve as the evaporator back plate.

Referring now to fig. 19, a transverse cross-sectional view of ice tubes separated from evaporator grid 1901 during dry harvesting of ice is shown. Compressed gas from the valve passes between ice 1905 and

resilient substrate layers

1902 and 1903, resulting in separation 1904.

Referring now to fig. 20, a transverse cross-sectional view of an ice tube ejection from an evaporator grid during dry harvest of ice is shown. Once the ice is mostly separated, the two or more seals 2002 separate to form a gap 2001, releasing the ice that falls by gravity toward the shredder.

Referring now to fig. 21, a cross-sectional view of an alternative ice tube ejection during dry harvest of ice is shown. The first tube type 2101 may have a star-shaped cross-section that is inverted into a flower shape to eject ice. The second tube type 2102 may have a removable overlapping section 2103 that allows the circumference of the tube 2102 to be increased to eject ice. These shapes can be used in a household refrigerator ice maker which produces cake-shaped ice cubes with half-rounded edges.

Optionally, dry pop-up is incorporated into an ice making apparatus as part of a commercial or household refrigerator, such as the Whirlpool EZ Connect Icemaker Kit (Whitpump EZ Connect Icemaker Kit) for a top-grade freezer refrigerator (model # ECKMFEZ 2). For example, each chamber in the small grid comprises an elastic base plate and a valve for inserting compressed air between the ice formed and the elastic base plate. A household refrigerator ice maker may include a metal ice mold with a heater placed at the bottom of the ice mold to melt ice and release the ice during wet harvest. The rotating ejector blades may be used to eject ice from the ice mold by the rotating motion of the blades. At the beginning of the process, water may be injected into one ice bin and flow through small water passages and/or channels (e.g., small openings in the side walls of the ice bin) to all other ice bins. When the water freezes, 6 to 9 ice cubes are formed, connected by small ice bridges. During the wet harvest phase, the small ice bridges melt and the ice cubes separate, thereby creating beautiful ice cubes. During dry harvesting, the ice bridge remained intact. To reduce the impact of ice bridges, one or more of the following options may be applied:

(i) increasing the volume, size and/or shape of the rotating ejector blades, and using the blades in each chamber to reduce the water injected into each chamber,

(ii) an intervening volume, such as a lid, is used during filling, so that water can diffuse into the adjacent ice compartment,

(iii) removing additional volume in the ice chamber, allowing water on the bridge to migrate into the chamber, and/or

(iv) Similar situation applies.

Optionally, the flexible substrate is connected to a suction pump and during the separation phase the suction pump pulls the flexible substrate away from the formed ice.

Optionally, ice tiles having a thickness of less than 22 mm are produced and ejected using a dry ejection embodiment. For example, ice cubes having a thickness between 5mm and 25 mm are produced in an ice maker and dry ejections are used to eject ice lumps from a resilient base plate. For example, ice cubes made from ice blocks having a thickness of less than 20 millimeters have a higher surface area than typical ice cubes and therefore cool liquid more efficiently than typical ice cubes. Furthermore, making thinner tiles can be made more efficiently, e.g., with higher evaporator temperatures and can better maintain tile thickness using a dry ejection embodiment rather than wet ejection. For example, a 10 mm thick block of ice may use an evaporator temperature of-10 degrees Celsius, while a 20 mm thick block of ice may use an evaporator temperature of-20 degrees Celsius.

Optionally, the elastomeric substrate may include a combination of polymers, such as derivatives of polysiloxanes (dimethylsiloxane, H-methylsiloxane, etc.), derivatives of epoxy-based photoresists (SU-8, etc.), derivatives of polyethylene (PE, PET, etc.), derivatives of Polycarbonate (PC), derivatives of polyamides (PA6), cellulose-containing materials (e.g., cellulose acetate), rubber, and/or the like.

Optionally, the resilient substrate may include inorganic materials such as metal oxides (titanium dioxide, zinc oxide, etc.), dielectric materials (silicon dioxide, aluminum oxide, etc.), metals (aluminum, copper, zinc, stainless steel, etc.), and/or the like. Specialized areas of increased or decreased flexibility may be provided around the corners to allow compressed gas to pass through most locations between the ice and the grid. The metal cover of the resilient base may be shaped as a "spring shape" with rounded edges to achieve greater flexibility. Optionally, the edge is less flexible, thereby forming a seal in the flexible region. For example, the rigid region of the resilient substrate may allow a seal to be formed around the edge of the ice sheet during dry ejection.

Optionally, the elastic substrate may include a highly conductive polymer, such as a derivative of polythiophene (poly 3, 4-ethylenedioxythiophene, PEDOT, polymethylthiophene, PMT, etc.), a derivative of polyphenylene (poly (p-phenylene sulfide), PPS, poly (p-phenylene vinylene), PPV, etc.), and/or the like.

Optionally, the resilient substrate may include thermally conductive additives such as thermally conductive nano/micro particles of carbon, gold, or the like, thermally conductive nanowires or tubes made of carbon, gold, silver, or the like, and/or the like. Optionally, nodal welding techniques are used to increase conduction, such as thermally conductive micro-grids, millimeter-mesh made of aluminum/steel/copper, and/or the like.

Optionally, the resilient substrate may include a hydrophobic material and may be made of manganese oxide polystyrene, zinc oxide polystyrene, precipitated calcium carbonate, carbon nanotubes, silica, derivatives of fluorinated materials, and/or the like.

The following are examples of valves, substrates, and/or the like that have been found to facilitate dry ejection of ice nuggets(s).

For example, the elastic substrate is composed of a material that deforms 10 microns at a pressure of 0.3 bar. At a thickness of 100 microns, the strain is 0.1 and the modulus of elasticity is 300 kilopascals. These are rough empirical estimates and are used to understand the overall behavior of the resilient substrate. The resilient substrate may have a non-linear resilient behavior as the incompressible material flows into the air voids in the grid, thereby changing the thickness of the resilient substrate between the ice and the grid.

For example, the elastomeric substrate comprises a flexible Room Temperature Vulcanized (RTV) silicone layer (0.2mm thickness, shore hardness 40A) and a hard phosphor bronze layer (0.1mm thickness). The valve orifice with the flexible member and the 1.5mm compressed air outlet orifice is capable of separating ice at a pressure of 1/5 bar above ambient pressure and a temperature of-15 degrees celsius. For example, without the flexible component of the valve, even a gas pressure more than 7 bar above ambient pressure cannot separate ice lumps from the exemplary resilient base plate.

For example, for a resilient substrate having a thickness of 0.25 mm, a thermal conductivity of 11Wm/K and a Shore hardness of 60(OO scale), the volume of ice would only decrease by 3% for the same freezing time.

Optionally, one embodiment includes an ice support plate for using dry harvest technology in an ice making machine. For example, the ice support plate prevents bending stresses in the ice lump/brick/plate and eventual cracks generated in the ice that prevent the propagation of the separation between the elastic base plate and the ice. For example, an ice support plate is a rigid structure with contact points on an ice plug and is attached to the ice support plate when ice freezes. This may increase the mechanical strength of the ice sheet during the stage of ice detachment from the resilient base.

Referring now to fig. 22, a schematic diagram of an embodiment 2200 for dry ejection using a splash curtain is shown. A water curtain or splash curtain 2201 located in front of the evaporator 2202 prevents water from splashing out of the evaporator during freezing. At the end of the freezing process, water curtain 2201 is pushed by ice tile 2203. After dry ejection, ice tiles 2203 fall into a storage bin.

Referring now to fig. 23, a schematic diagram of an embodiment of a dry pop-up with a splatter curtain prior to ice formation is shown. Optionally, an ice support plate 2301 attached to, replacing, separate from, etc. a splash curtain can be used for a dry harvest ice maker. Ice support plate 2301 may include ribs 2302, which ribs 2302 may follow a certain geometry and/or orientation, such as horizontal, vertical, angled ribs, dots, and/or the like. During the formation of the ice sheet, water 2303 flows between the evaporator 2304 and the ice support plate 2301 and begins to freeze on the evaporator 2304. Unfrozen water 2303B flows downward to water container 2305. The ice support plate 2301 may be used as a splash curtain.

Referring now to fig. 24, a schematic diagram of an embodiment of a dry pop-up with a splatter curtain after ice formation is shown. At the end of the freezing process, ice tiles 2401 may be formed over evaporator 2304 and may be bonded to ice support plate ribs 2302. The ice brick 2401 may comprise an ice bridge 2402, for example for separating the ice brick 2401 into ice cubes.

Referring now to fig. 25, a schematic diagram of an embodiment of a dry pop-up with a splash curtain during ice pop-up is shown. After the freezing process is complete, compressed air 2501 may be driven between the evaporator 2304 and the ice bank 2401 and separation begins (i.e., as part of the dry harvest process). The ice support plate 2301 reinforces the ice bridge 2402 and prevents the ice bridge 2402 from breaking during dry ejection by providing mechanical support to the ice bridge 2402 using ribs 2302 connected to the support plate 2301. Optionally, water may be driven between the support plate 2301 and the ice brick 2401 to separate the two, optionally in addition to compressed air 2501, and excess water 2303B may flow into the water collection container 2305. For example, water heats the support plate 2301 and separates the ribs 2302 from the ice bank 2401.

The ice tiles 2401 (which may be bonded together) with the ice support plate 2301 may be pushed away from the evaporator 2304 (i.e., an ejection process). Water may flow again between the evaporator 2304 and the ice brick 2401 or/and the ice brick 2401 coupled to the ice support plate 2301 and the support plate 2301, thereby heating the ice brick 2401 and releasing the ice brick 2401 from the ice support plate 2301, and at the same time may freeze on the evaporator 2304. The pushing mechanism for the ice bank may be an electric or pneumatic based actuator mechanism that can push or rotate the ice bank 2401 and the ice support plate 2301.

Referring now to fig. 26, a schematic diagram of an embodiment of a dry pop-up with a splash curtain after ice pop-up is shown. Ice tiles 2401 may be released from ice support plate 2301 and dropped into a storage bin.

The ice support plate 2301 may be used on vertical or horizontal evaporators and may have water inlet and outlet holes, air inlet and outlet holes, soft regions with low shore hardness polymers (i.e., elastomers) that may aid in the air progression during separation for dry harvesting.

Optionally, the ice support plate may include regions of higher flexibility than other regions, thereby allowing for the creation of ice tiles without ice bridges by pressing the ice support plate onto the resilient base plate.

Optionally, the ice support plate may include air channels for applying compressed air to the grid for ice brick separation, to prevent buckling during ejection, and the like. Optionally, the air channel applies suction to the ice bank and/or the resilient base.

Optionally, the grid and/or the resilient base plate are made of strips and welded together in order to create a high draft angle.

Optionally, the straps include notches to aid in assembling the grid.

Optionally, the grid has shallow ice-forming walls. For example, the wall height of the grid for dry ice ejection is 10 millimeters. For example, the wall height of the grid for dry ice ejection is between 3 and 20 millimeters. For example, the resilient base wall height is 4mm and the wall is attached to a flat evaporator pan, such as an evaporator back (without straps), to enhance ice machine cost reduction.

Throughout this application, various embodiments of the invention may be presented in a range format. It is to be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub-ranges as well as individual numerical values within that range. For example, it is contemplated that the description of a range such as 1 to 6 should be considered to have the particular disclosed subranges, e.g., 1 to 3, 1 to 4,1 to 5, 2 to 4, 2 to 6, 3 to 6, etc., as well as individual numbers within that range, e.g., 1, 2, 3,4, 5, and 6. This applies regardless of the breadth of the range.

Whenever a numerical range is indicated herein, it is intended to include any number of the referenced number (fractional or integer) within the indicated range. The phrases "range between" a first indicated number and "a second indicated number" and "range from" the first indicated number "to" the second indicated number "are used interchangeably herein and are meant to include the first indicated number and the second indicated number and all fractional and integer numbers therebetween.

In the description and claims of this application, each of the words "comprising," "including," and "having" and forms thereof are not necessarily limited to the elements in the list with which the words are associated. In addition, this application is intended to control in the event of inconsistencies between this application and any document incorporated by reference.

The flowchart and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.

The description of various embodiments of the present invention has been presented for purposes of illustration but is not intended to be exhaustive or limited to the disclosed embodiments. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terms used herein were chosen in order to best explain the principles of the embodiments, the practical application, or technical improvements to the techniques found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.

Claims

1. An ice making machine comprising:

a pressure source configured to provide a gas at a pressure above ambient pressure;

an evaporator grid, the evaporator grid comprising:

(i) the back plate of the evaporator is provided with a plurality of grooves,

(ii) a resilient substrate disposed over the evaporator backplate configured to resiliently contract in thickness toward the evaporator backplate by at least 10 microns, an

(iii) A gas valve in fluid communication with the pressure source and configured to inject a compressed fluid between an ice plug formed in the evaporator grid and the evaporator grid; and

at least one controller configured to:

(a) operating a mechanical element to induce a separation between the elastic base plate and the ice plug formed in the evaporator grid, an

(b) Operating the pressure source to inject the gas into a space formed by the separation, wherein the gas has a pressure higher than ambient pressure.

2. The ice-making machine of claim 1, wherein said evaporator grid further comprises an ice sealing mechanism along a perimeter of said evaporator back plate, wherein said ice sealing mechanism is configured to prevent escape of said gas until said ice plug is mostly detached from said resilient base plate, and is configured for later popping said ice plug into a dispenser.

3. The ice maker of claim 2, wherein the ice sealing mechanism comprises at least one element from the group consisting of:

(a) an angled surface, wherein the angled surface is substantially rigid;

(b) a rigid region of the resilient substrate;

(c) a groove;

(d) a heating element;

(e) a mechanical control lever;

(f) a compressible pad disposed within the groove; and

(g) a removable sealing frame.

4. The ice maker of claim 1, wherein the gas valve comprises a gas outlet recess and at least one element from the group consisting of:

(a) an inflatable cushion in mechanical communication with the gas outlet recess;

(b) a center pin configured to seal the gas outlet notch when ice forms in the evaporator grid;

(c) a piston connected to one edge of the gas outlet recess and configured to slide away from the gas outlet recess when the gas is applied; and

(d) a central pin configured to slide out of the gas valve towards the ice plug and to assist in ejecting the ice plug.

5. The ice-making machine of claim 1, wherein said evaporator back plate comprises a plurality of voids for receiving at least a portion of said resilient base plate when said resilient base plate resiliently contracts.

6. The ice maker of claim 1, wherein the resilient base plate comprises a plurality of flexible regions, at least one of the plurality of flexible regions being present along each corner of the resilient base plate.

7. The ice maker of claim 1, wherein the ice plug comprises a plurality of ice pieces, and the ice maker is an ice cube maker.

8. The ice-making machine of claim 1, wherein said ice plug comprises at least one ice tube, said evaporator grid is an array of evaporator tubes, and said ice-making machine is an ice tube machine.

9. The ice maker of claim 1, wherein the ice plug comprises at least one ice slab, and the ice maker is a slab ice machine.

10. The ice maker of claim 1, wherein the gas is at a pressure at least 0.1 bar above ambient pressure.

11. The ice-making machine of claim 1, wherein said gas is at ambient pressure and said evaporator grid is maintained at a pressure at least 0.1 bar below ambient pressure using a fluid connection with a suction pump.

12. The ice maker of claim 1, further comprising a rigid ice support plate opposite the resilient base plate for preventing the ice mound from bending during ejection.

13. The ice maker of claim 12, wherein the rigid ice support plate comprises raised ridges.

14. The ice maker of claim 12, further comprising a splash plate, and wherein the rigid ice support plate is incorporated into the splash plate.

15. The ice maker of claim 12, further comprising a splash plate, and wherein the rigid ice support plate is connected to the splash plate.

16. A method for ejecting ice from an ice maker comprising using at least one controller configured to command the actions of:

introducing a gas into a gas valve of an evaporator back plate connected to an evaporator grid, wherein the gas is at a pressure higher than ambient pressure;

inducing a separation between an ice plug and a resilient base plate in an area around the gas valve by mechanically manipulating an outlet recess of the gas valve, wherein the resilient base plate is disposed over the evaporator back plate, and wherein the evaporator back plate comprises a plurality of voids; and

ejecting the gas to expand the separation between the ice nuggets and the resilient base by the resilient base contracting toward the evaporator backplate until at least some of the ice nuggets separate from the resilient base.

17. The method of claim 16, further comprising the act of ejecting the ice plug from the evaporator grid by:

(a) breaking a seal between the ice plug and the evaporator grid around a perimeter of the resilient base plate, and

(b) an ejection force is applied on the ice plug in the direction of the ice dispenser.

18. The method of claim 17, wherein the seal is created during formation of the ice lump on an angled surface, wherein the angled surface is substantially rigid.

19. The method of claim 17, wherein the seal is created during formation of the ice plug in the groove.

20. The method of claim 17, wherein the breaking of the seal comprises at least one action from the group consisting of:

(a) activating the heating element;

(b) operating a mechanical control lever;

(c) expanding a compressible pad disposed within the groove; and

(d) the removable sealing frame is moved.

21. The method of claim 17, wherein said ejection force is applied by the action of sliding a central pin out of said gas valve towards said ice plug to assist in ejecting said ice plug.

22. The method of claim 17 further comprising the act of applying a force at least partially toward a resilient base during said separating of said ice plug, and further comprising releasing said force during said ejecting of said ice plug.

23. The method of claim 16, wherein the initiating comprises releasing the gas from the outlet notch and at least one action from the group consisting of:

(a) inflating a valve gasket in mechanical communication with the gas outlet notch;

(b) moving a center pin configured to seal the gas outlet notch when ice is formed in the evaporator grid;

(c) sliding a piston connected to one edge of the gas outlet recess in a direction away from the gas outlet recess when the gas is applied;

(d) heating ice around the valve; and

(e) low pressure gas is leaked into the water before ice formation.

24. The method of claim 16, wherein the contraction of the resilient substrate facilitates compression of at least a portion of the resilient substrate into the plurality of voids in the evaporator back plate.

25. The method of claim 16, wherein the gas passes through corners in the resilient substrate at a plurality of flexible regions, at least one of the plurality of flexible regions being present along each corner of the resilient substrate.

26. The method of claim 16, wherein the gas is at ambient pressure and the evaporator grid is maintained at a pressure at least 0.1 bar below ambient pressure using a fluid connection with a suction pump.

27. The method of claim 16, wherein the gas is at a pressure of at least 0.1 bar above ambient pressure.

28. The method of claim 16, wherein the shrinkage of the resilient substrate toward the evaporator back plate is at least 10 microns.

29. The method of claim 16, wherein said shrinking of said resilient base towards said evaporator backplate continues until a majority of said ice mounds separate from said resilient base.