Patent Description:
Ice makers are well-known and in extensive commercial and residential use. One type of ice maker includes an evaporator assembly that comprises a freeze plate which defines a plurality of ice molds in a two-dimensional vertical grid. Refrigerant tubing extends along the back of the freeze plate and forms an evaporator configured to cool the freeze plate. A water distributor is positioned above the freeze plate to direct water onto the freeze plate that freezes into ice in the molds. Documents <CIT> and <CIT> are relevant prior art documents and disclose distributors for ice makers.

The present invention is disclosed in the independen claim <NUM>.

According to an example not being part of the present invention it is disclosed an icemaker which comprises a freeze plate defining a plurality of molds in which the ice maker is configured to form ice. The freeze plate has a front defining open front ends of the molds, a back defining enclosed rear ends of the molds, a top portion and a bottom portion spaced apart along a height, and a first side portion and a second side portion spaced apart along a width. A distributor adjacent the top portion of the freeze plate is configured to direct water imparted through the distributor to flow downward along the front of the freeze plate along the width of the freeze plate. The distributor comprises a first end portion and a second end portion spaced apart along a width of the distributor. A bottom wall extends widthwise from the first end portion to the second end portion and extends generally forward from an upstream end portion to a downstream end portion. The distributor is configured to direct the water imparted therethrough to flow in a generally forward direction from the upstream end portion to the downstream end portion. A weir extends upward from the bottom wall at a location spaced apart between the upstream end portion and the downstream end portion. The weir is configured so that the water flows across the weir as it flows along the bottom wall from the upstream end portion to the downstream end portion. The bottom wall comprises a ramp surface, immediately upstream of the weir, sloping upward in the generally forward direction.

In another example not being part of the present invention an ice maker comprises a freeze plate defining a plurality of molds in which the ice maker is configured to form ice. The freeze plate has a front defining open front ends of the molds, a back defining enclosed rear ends of the molds, a top portion and a bottom portion spaced apart along a height, and a first side portion and a second side portion spaced apart along a width. A distributor adjacent the top portion of the freeze plate is configured to direct water imparted through the distributor to flow downward along the front of the freeze plate along the width of the freeze plate. The distributor comprises a first end portion and a second end portion spaced apart along a width of the distributor. A bottom wall extends widthwise from the first end portion to the second end portion and extends generally forward from an upstream end portion to a downstream end portion. The distributor is configured to direct the water imparted therethrough to flow in a generally forward direction from the upstream end portion to the downstream end portion. The downstream end portion of the bottom wall defines a downwardly curving surface tension curve. The downwardly curving surface tension curve is configured so that surface tension causes the water imparted through the distributor to adhere to the curve and be directed downward by the curve toward the top end portion of the freeze plate.

In another example not being part of the present invention an ice maker comprises a freeze plate defining a plurality of molds in which the ice maker is configured to form ice. The freeze plate has a front defining open front ends of the molds, a back defining enclosed rear ends of the molds, a top portion and a bottom portion spaced apart along a height, and a first side portion and a second side portion spaced apart along a width. A distributor adjacent the top portion of the freeze plate is configured to direct water imparted through the distributor to flow downward along the front of the freeze plate along the width of the freeze plate. The distributor comprises a first end portion and a second end portion spaced apart along a width of the distributor. A bottom wall extends widthwise from the first end portion to the second end portion and extends generally forward from an upstream end portion to a downstream end portion. The distributor is configured to direct the water imparted therethrough to flow in a generally forward direction from the upstream end portion to the downstream end portion. An overhanging front wall has a bottom edge margin spaced apart above the bottom wall adjacent the downstream end portion thereof such that a flow restriction is defined between the bottom wall and the overhanging front wall. The flow restriction comprises a gap extending widthwise between the first end portion and the second end portion of the distributor and is configured to restrict a rate at which water flows through the flow restriction to the downstream end portion of the bottom wall.

In another example not being part of the present invention an ice maker comprises a freeze plate defining a plurality of molds in which the ice maker is configured to form ice. The freeze plate has a top portion and a bottom portion spaced apart along a height and a first side portion and a second side portion spaced apart along a width. A distributor extends along the width of the freeze plate adjacent the top portion of the freeze plate. The distributor is configured to direct water imparted through the distributor to flow from the top portion of the freeze plate to the bottom portion along the width of the freeze plate. The distributor comprises a first distributor piece and a second distributor piece. The second distributor piece is configured to be releasably coupled to the first distributor piece without separate fasteners to form the distributor.

In another example not being part of the present invention an ice maker comprises a freeze plate defining a plurality of molds in which the ice maker is configured to form ice. The freeze plate has a top portion and a bottom portion spaced apart along a height and a first side portion and a second side portion spaced apart along a width. A distributor adjacent the top portion of the freeze plate has a width extending along the width of the freeze plate. The distributor has an inlet and an outlet and defining a distributor flow path extending from the inlet to the outlet. The distributor is configured to direct water imparted through the distributor along the distributor flow path and discharge the water from the outlet such that the water flows from the top portion of the freeze plate to the bottom portion along the width of the freeze plate. The distributor comprises a first distributor piece and a second distributor piece. The second distributor piece is releasably coupled to the first distributor piece to form the distributor. The first distributor piece comprises a bottom wall defining a groove extending widthwise and the second distributor piece comprising a generally vertical weir defining a plurality of openings spaced apart along the width of the distributor. The weir has a free bottom edge margin received in the groove such that water flowing along the distributor flow path is inhibited from flowing through an interface between the bottom edge margin of the weir and the bottom wall and is directed to flow across the weir through the plurality of openings.

In another example not being part of the present invention an ice maker comprises an evaporator assembly comprising a freeze plate defining a plurality of molds in which the evaporator assembly is configured to form pieces of ice. The freeze plate has a front defining open front ends of the molds and a back extending along closed rear ends of the molds. An evaporator housing has a back and defines an enclosed space between the back of the freeze plate and the back of the evaporator housing. Refrigerant tubing is received in the enclosed space. Insulation substantially fills the enclosed space around the refrigerant tubing. A water system is configured to supply water to the freeze plate such that the water forms into ice in the molds. The evaporator housing includes a distributor piece formed from a single piece of monolithic material. The distributor piece is in direct contact with the insulation and has a bottom wall. The water system is configured direct the water to flow along the bottom wall as the water is supplied to the freeze plate.

In still another example not being part of the present invention an ice maker comprises an evaporator assembly comprising a freeze plate defining a plurality of molds in which the evaporator assembly is configured to form pieces of ice. The freeze plate has a front defining open front ends of the molds, a back extending along closed rear ends of the molds, a top wall formed from a single piece of monolithic material and defining a top end of at least one of the molds, and at least one stud joined to the top wall and extending upward therefrom. A distributor is configured to distribute water imparted through the distributor over the freeze plate so that the water forms into ice in the molds. The distributor comprises a distributor piece formed from a single piece of monolithic material. The distributor piece comprises a bottom wall defining a portion of a flow path along which the distributor directs water to flow through the distributor. A nut is tightened onto each stud against the distributor piece to directly mount the distributor on the freeze plate.

A distributor according to claim <NUM> for receiving water imparted through the distributor and directing the water to flow along a freeze plate of an ice maker so that the water forms into ice on the freeze plate comprises a rear wall adjacent an upstream end of the distributor, a bottom wall extending forward from the rear wall to a front end portion adjacent a downstream end of the distributor, and a tube protruding rearward from the rear wall. The rear wall has an opening immediately above the bottom wall through which the tube fluidly communicates with the distributor. The bottom wall comprises a rear section that slopes downward to the rear wall and a front section that slopes downward to the front end portion.

In another example not being part of the present invention it is disclosed an ice maker comprising an enclosure. A freeze plate is received in the enclosure. The freeze plate comprises a back wall and a front opposite the back wall. The freeze plate further comprises a perimeter wall extending forward from the back wall. The perimeter wall comprises a top wall portion, a bottom wall portion, a first side wall portion, and a second side wall portion. The first side wall portion and the second side wall portion define a width of the freeze plate. The freeze plate further comprises a plurality of heightwise divider plates extending from lower ends connected to the bottom wall portion to upper ends connected to the top wall portion and a plurality of widthwise divider plates extending from first ends connected to the first side wall portion to second ends connected to the second side wall portion. The heightwise divider plates and the widthwise divider plates are interconnected to define a plurality of ice molds inboard of the perimeter wall. Each widthwise divider plate defines a plurality of molds immediately above the divider plate and a plurality of molds immediately below the divider plate. Each widthwise divider plate slopes downward and forward away from the back wall of the freeze plate such that included angle between an upper surface of each widthwise divider plate and the back wall is greater than <NUM>° and less than <NUM>°. A distributor is configured to direct water imparted through the distributor to flow downward along the freeze plate along the width of the freeze plate. The freeze plate is supported in the enclosure so that the back wall of the freeze plate slants forward.

The drawings provide representations of embodiments of the present invention, and examples not being part of the present invention. For the avoidance of doubt, any figures falling outside of the scope of the appended claims are provided for reference only.

Referring to <FIG>, one example of an ice maker is generally indicated at reference number <NUM>. This example details exemplary features of the ice maker <NUM> that can be used individually or in combination to enhance ice making uniformity, ice harvesting performance, energy efficiency, assembly precision, and/or accessibility for repair or maintenance. One feature of the present example pertains to an evaporator assembly that includes an evaporator, a freeze plate, and a water distributor. As will be explained in further detail below, according to one or more examples, the parts of the evaporator assembly are integrated together into a single unit. Optionally, the water distributor includes a configuration of water distribution features that provides uniform water flow along the width of the freeze plate. In an example, the water distributor is configured to provide ready access to the interior of the distributor for repair or maintenance. In one or more examples, the evaporator assembly is configured to mount the freeze plate within the ice maker in an orientation that reduces the time it takes to passively harvest ice using gravity and heat. Other features of the ice maker <NUM> will also be described hereinafter. Though this example describes an ice maker that combines a number of different features, it will be understood that other ice makers can use any one or more of the features disclosed herein.

The disclosure begins with an overview of the ice maker <NUM>, before providing a detailed description of an exemplary embodiment, of an evaporator assembly.

Referring to <FIG>, which discloses an examplary refrigeration system of the ice maker <NUM>, the ice maker includes a compressor <NUM>, a heat rejecting heat exchanger <NUM>, refrigerant expansion device <NUM> for lowering the temperature and pressure of the refrigerant, an evaporator assembly <NUM> (broadly, an ice formation device), and a hot gas valve <NUM>. As shown, the heat rejecting heat exchanger <NUM> may comprise a condenser for condensing compressed refrigerant vapor discharged from the compressor <NUM>. In other alternatives, for example, in refrigeration systems that utilize carbon dioxide refrigerants where the heat of rejection is trans-critical, the heat rejecting heat exchanger is able to reject heat from the refrigerant without condensing the refrigerant. The illustrated evaporator assembly <NUM> integrates an evaporator <NUM> (e.g., serpentine refrigerant tubing), a freeze plate <NUM>, and a water distributor <NUM> into one unit, as will be described in further detail below. Hot gas valve <NUM> is used, in one or more embodiments, to direct warm refrigerant from the compressor <NUM> directly to the evaporator <NUM> to remove or harvest ice cubes from the freeze plate <NUM> when the ice has reached the desired thickness.

The refrigerant expansion device <NUM> can be of any suitable type, including a capillary tube, a thermostatic expansion valve or an electronic expansion valve. In certain embodiments, where the refrigerant expansion device <NUM> is a thermostatic expansion valve or an electronic expansion valve, the ice maker <NUM> may also include a temperature sensor <NUM> placed at the outlet of the evaporator tubing <NUM> to control the refrigerant expansion device <NUM>. In other examples, where the refrigerant expansion device <NUM> is an electronic expansion valve, the ice maker <NUM> may also include a pressure sensor (not shown) placed at the outlet of the evaporator tubing <NUM> to control the refrigerant expansion device <NUM> as is known in the art. In certain examples that utilize a gaseous cooling medium (e.g., air) to provide condenser cooling, a condenser fan <NUM> may be positioned to blow the gaseous cooling medium across the condenser <NUM>. A form of refrigerant cycles through these components via refrigerant lines 28a, 28b, 28c, 28d.

Referring still to <FIG>, a water system of the illustrated ice maker <NUM> includes a sump assembly <NUM> that comprises a water reservoir or sump <NUM>, a water pump <NUM>, a water line <NUM>, and a water level sensor <NUM>. The water system of the ice maker <NUM> further includes a water supply line (not shown) and a water inlet valve (not shown) for filling sump <NUM> with water from a water source (not shown). The illustrated water system further includes a discharge line <NUM> and a discharge valve <NUM> (e.g., purge valve, drain valve) disposed thereon for draining water from the sump <NUM>. The sump <NUM> may be positioned below the freeze plate <NUM> to catch water coming off of the freeze plate such that the water may be recirculated by the water pump <NUM>. The water line <NUM> fluidly connects the water pump <NUM> to the water distributor <NUM>. During an ice making cycle, the pump <NUM> is configured to pump water through the water line <NUM> and through the distributor <NUM>. As will be discussed in greater detail below, the distributor <NUM> includes water distribution features that distribute the water imparted through the distributor evenly across the front of the freeze plate <NUM>. In an example, the water line <NUM> is arranged in such a way that at least some of the water can drain from the distributor through the water line and into the sump when ice is not being made.

In an embodiment, the water level sensor <NUM> comprises a remote air pressure sensor <NUM>. It will be understood, however that any type of water level sensor may be used in the ice maker <NUM> including, but not limited to, a float sensor, an acoustic sensor, or an electrical continuity sensor. The illustrated water level sensor <NUM> includes a fitting <NUM> that is configured to couple the sensor to the sump <NUM> (see also <FIG>). The fitting <NUM> is fluidly connected to a pneumatic tube <NUM>. The pneumatic tube <NUM> provides fluid communication between the fitting <NUM> and the air pressure sensor <NUM>. Water in the sump <NUM> traps air in the fitting <NUM> and compresses the air by an amount that varies with the level of the water in the sump. Thus, the water level in the sump <NUM> can be determined using the pressure detected by the air pressure sensor <NUM>. Additional details of a water level sensor comprising a remote air pressure sensor are described in <CIT>.

In the illustrated embodiment, the sump assembly <NUM> further comprises a mounting plate <NUM> that is configured to operatively support both the water pump <NUM> and the water level sensor fitting <NUM> on the sump <NUM>. An exemplary embodiment of a mounting plate <NUM> is shown in <FIG>.

The mounting plate <NUM> may define an integral sensor mount <NUM> for operatively mounting sensor fitting <NUM> on the sump <NUM> at a sensing position at which the water level sensor <NUM> is operative to detect the amount of water in the sump. The mounting plate <NUM> may also define a pump mount <NUM> for mounting the water pump <NUM> on the sump <NUM> for pumping water from the sump through the water line <NUM> and the distributor <NUM>. Each of the sensor mount <NUM> and the pump mount <NUM> may include locking features that facilitate releasably connecting the respective one of the water level sensor <NUM> and the water pump <NUM> to the sump <NUM>.

Referring again to <FIG>, the ice maker <NUM> may also include a controller <NUM>. The controller <NUM> may be located remote from the ice making device <NUM> and the sump <NUM> or may comprise one or more onboard processors, in one or more embodiments. The controller <NUM> may include a processor <NUM> for controlling the operation of the ice maker <NUM> including the various components of the refrigeration system and the water system. The processor <NUM> of the controller <NUM> may include a non-transitory processor-readable medium storing code representing instructions to cause the processor to perform a process. The processor <NUM> may be, for example, a commercially available microprocessor, an application-specific integrated circuit (ASIC) or a combination of ASICs, which are designed to achieve one or more specific functions, or enable one or more specific devices or applications. In certain examples, the controller <NUM> may be an analog or digital circuit, or a combination of multiple circuits. The controller <NUM> may also include one or more memory components (not shown) for storing data in a form retrievable by the controller. The controller <NUM> can store data in or retrieve data from the one or more memory components.

In various examples, the controller <NUM> may also comprise input/output (I/O) components (not shown) to communicate with and/or control the various components of ice maker <NUM>. In certain examples, the controller <NUM> may receive inputs such as, for example, one or more indications, signals, messages, commands, data, and/or any other information, from the water level sensor <NUM>, a harvest sensor for determining when ice has been harvested (not shown), an electrical power source (not shown), an ice level sensor (not shown), and/or a variety of sensors and/or switches including, but not limited to, pressure transducers, temperature sensors, acoustic sensors, etc. In various examples, based on those inputs for example, the controller <NUM> may be able to control the compressor <NUM>, the condenser fan <NUM>, the refrigerant expansion device <NUM>, the hot gas valve <NUM>, the water inlet valve (not shown), the discharge valve <NUM>, and/or the water pump <NUM>, for example, by sending, one or more indications, signals, messages, commands, data, and/or any other information to such components.

Referring to <FIG>, one or more components of the ice maker <NUM> may be stored inside of an enclosure <NUM> of the ice maker <NUM> that defines an interior space. For example, portions or all of the refrigeration system and water system of the ice maker <NUM> described above can be received in the interior space of the enclosure <NUM>. In the illustrated example, the enclosure <NUM> is mounted on top of an ice storage bin assembly <NUM>. The ice storage bin assembly <NUM> includes an ice storage bin <NUM> having an ice hole (not shown) through which ice produced by the ice maker <NUM> falls. The ice is then stored in a cavity <NUM> until retrieved. The ice storage bin <NUM> further includes an opening <NUM> which provides access to the cavity <NUM> and the ice stored therein. The cavity <NUM>, ice hole (not shown), and opening <NUM> are formed by a left wall 33a, a right wall 33b, a front wall <NUM>, a back wall <NUM> and a bottom wall (not shown). The walls of the ice storage bin <NUM> may be thermally insulated with various insulating materials including, but not limited to, fiberglass insulation or open- or closed-cell foam comprised, for example, of polystyrene or polyurethane, etc. in order to retard the melting of the ice stored in the ice storage bin <NUM>. A door <NUM> can be opened to provide access to the cavity <NUM>.

The illustrated enclosure <NUM> is comprised of a cabinet <NUM> (broadly, a stationary enclosure portion) and a door <NUM> (broadly, a movable or removable enclosure portion). In <FIG>, the door <NUM> of the ice storage bin assembly <NUM> is raised so that it partially obscures the ice maker door <NUM>. The door <NUM> is movable with respect to the cabinet <NUM> (e.g., on a hinge) to selectively provide access to the interior space of the ice maker <NUM>. Thus, a technician may open the door <NUM> to access the internal components of the ice maker <NUM> through a doorway (not shown; broadly, an access opening) as required for repair or maintenance. In one or more other examples, the door may be opened in other ways, such as by removing the door assembly from the cabinet.

Referring to <FIG>, the illustrated ice maker <NUM> comprises a one-piece support no that is configured to support several components of the ice maker inside the enclosure <NUM>. For example, the illustrated support no is configured to support the sump <NUM>, the mounting plate <NUM>, and the evaporator assembly <NUM> at very precise positions to limit the possibility of misplacement of these components. The inventors have recognized that ice maker control schemes that use water level as a control input require accurate placement of the water level sensor in the sump. If the position of the water level sensor deviates from the specified position by even a small amount (e.g., millimeters or less), the control scheme can be disrupted. The inventors have further recognized that the aggregated dimensional tolerances of the parts of conventional assemblies for mounting internal ice maker components can lead to misplacement. Still further, the inventors have recognized that precisely positioning an evaporator assembly in an ice maker can enhance gravity-driven ice making and ice-harvesting performance.

In the illustrated example, the support no includes a base <NUM> and a vertical support wall <NUM>. The illustrated vertical support wall comprises a first side wall portion <NUM>, a second side wall portion <NUM>, and a back wall portion <NUM> extending widthwise between the first and second side wall portions. A large opening <NUM> extends widthwise between the front end margins of the side wall portions <NUM>, <NUM>. When the ice maker <NUM> is fully assembled, this opening <NUM> is located adjacent a front doorway <NUM> (<FIG>) of the enclosure <NUM> such that a technician can access the components supported on the vertical wall through the opening when the door <NUM> is open.

Each side wall portion <NUM>, <NUM> includes an integral evaporator mount <NUM> (broadly, a freeze plate mount). The evaporator mounts <NUM> are configured to support the evaporator assembly <NUM> at an operative position in the ice maker <NUM>. Each side wall portion <NUM>, <NUM> further comprises an integral mounting plate mount <NUM> that is spaced apart below the evaporator mount <NUM>. The mounting plate mount <NUM> is configured to support the mounting plate <NUM> so that the mounting plate can mount the water level sensor fitting <NUM> and the pump <NUM> at operative positions in the ice maker <NUM>. An integral sump mount <NUM> for attaching the sump <NUM> to the ice maker is spaced apart below the mounting plate mount <NUM> of each side wall portion <NUM>, <NUM>. In <FIG>, only the mounts <NUM>, <NUM>, <NUM> defined by the right side wall portion <NUM> are shown, but it will be understood that the left side wall portion <NUM> has substantially identical, mirror-image mounts in the illustrated example.

At least one of the side wall portions <NUM>, <NUM> that defines the mounts <NUM>, <NUM>, <NUM> is formed from a single piece of monolithic material. For example, in one or more embodiments, the entire vertical support wall <NUM> is formed from a single monolithic piece of material. In the illustrated example, the entire support <NUM>, including the base <NUM> and the vertical support wall <NUM>, is formed from a single piece of monolithic material. In one or more examples, the support <NUM> is a single molded piece. In the illustrated example, the monolithic support <NUM> is formed by compression molding. Forming the support <NUM> from a single piece eliminates the stacking of tolerances that occurs in a multi-part support assembly and thereby increases the accuracy of the placement of the parts that are mounted on the support.

The evaporator mounts <NUM> are configured to mount the evaporator assembly <NUM> on the vertical support wall <NUM> in the enclosure <NUM> such that the freeze plate <NUM> slants forward. To accomplish this, each evaporator mount <NUM> in the illustrated example comprises a lower connection point <NUM> and an upper connection point <NUM> forwardly spaced from the lower connection point. As shown in <FIG>, the connection points <NUM>, <NUM> are spaced apart along an imaginary line IL1 that is oriented at a forwardly slanted angle α with respect to a plane BP the back wall portion <NUM> of the vertical support wall <NUM>. In use, the ice maker <NUM> is positioned so that the plane BP of the back wall portion <NUM> is substantially parallel to a plumb vertical axis VA. As such, the imaginary line IL1 slants forward with respect to the plumb vertical axis VA at the angle o.

In the illustrated example, each of the upper and lower connection points <NUM>, <NUM> comprises a screw hole. In use, the evaporator <NUM> is positioned between the side wall portions <NUM>, <NUM>, and a screw (not shown) is placed through each screw hole into a corresponding pre-formed screw hole associated with the evaporator assembly <NUM>. As explained below, the pre-formed evaporator screw-holes are arranged so that, when they are aligned with the evaporator mount screw holes <NUM>, <NUM>, the freeze plate <NUM> slants forward. It will be appreciated that an integral evaporator mount can include other types of connection points besides screw holes in one or more examples. For example, it is expressly contemplated that one or both of the screw holes <NUM>, <NUM> could be replaced by an integrally formed stud or other structure that can be used to register and attach a freeze plate to the support at the proper position.

Each mounting plate mount <NUM> comprises a pair of generally horizontally spaced tapered screw holes <NUM> (broadly, connection points). Similarly, each sump mount <NUM> comprises a pair of generally horizontally spaced mounting holes <NUM> (broadly, connection points). Again, the holes <NUM>, <NUM> of the mounting plate mount <NUM> and the sump mount <NUM> could be replaced with other types of integral connection points in one or more examples.

As shown in <FIG>, in one or more examples, the sump <NUM> is generally sized and arranged for being received in the space between the side wall portions <NUM>, <NUM> of the vertical support wall <NUM>. Each of a first end portion and a second end portion of the sump <NUM> that are spaced apart widthwise includes a pair of projections <NUM> at spaced apart locations. The projections <NUM> on each end portion of the sump <NUM> are configured to be received in the pair of mounting holes <NUM> defined by a respective one of the sump mounts <NUM>. The projections <NUM>, by being received in the mounting holes <NUM>, position the sump <NUM> at a precisely specified position along the height of the support <NUM>. In addition, a screw (not shown) is inserted through each mounting hole <NUM> and threaded into each projection <NUM> to fasten the sump <NUM> onto the support <NUM> at the specified position.

Like the sump <NUM>, the illustrated mounting plate <NUM> comprises a first end portion and a second end portion that are spaced apart widthwise. Each end portion of the mounting plate <NUM> defines a pair pre-formed screw holes that are configured to be aligned with the screw holes <NUM> of the corresponding mount <NUM> of the support <NUM>. Screws (broadly, mechanical fasteners; not shown) pass through the screw holes <NUM> and thread into the holes that are pre-formed in the mounting plate <NUM> to connect the mounting plate to the support <NUM> at a precisely specified position along the height of the support. In one or more examples, countersunk screws (e.g., screws with tapered heads) are used to connect the mounting plate <NUM> to the support <NUM>. The countersunk screws self-center in the tapered screw holes <NUM>.

It can be seen that the one-piece support <NUM> with integral mounts <NUM>, <NUM>, <NUM> can be used to ensure that the evaporator assembly <NUM>, the mounting plate <NUM>, and the sump <NUM> are supported in the ice maker <NUM> at the specified position. The support no can thereby position the freeze plate <NUM> to optimally balance desired performance characteristics, such as water distribution during ice making and ease/speed of ice-harvesting. Further, the support <NUM> can position the mounting plate <NUM> with respect to the sump <NUM> so that the pressure sensor fitting <NUM> mounted in the sensor mount <NUM> is precisely positioned with respect to the sump for accurately detecting the water level using the sensor <NUM>. Likewise, the support <NUM> positions the mounting plate <NUM> with respect to the sump <NUM> so that the pump <NUM> is precisely positioned for pumping water from the sump <NUM> through the ice maker <NUM> when the pump is mounted on the pump mount <NUM>.

Referring to <FIG>, an example of the freeze plate <NUM> will now be described, before turning to other components of the evaporator assembly <NUM> that attach the freeze plate to the support <NUM>. The freeze plate <NUM> defines a plurality of molds <NUM> in which the ice maker <NUM> is configured to form ice. The freeze plate <NUM> has a front defining open front ends of the molds <NUM>, a back defining enclosed rear ends of the molds, a top portion and a bottom portion spaced apart along a height HF, and a right side portion (broadly, a first side portion) and a left side portion (broadly, a second side portion) spaced apart along a width WF.

Throughout this disclosure, when the terms "front," "back," "rear," "forward," "rearward," and the like are used in reference to any part of the evaporator assembly <NUM>, the relative positions of the open front ends and enclosed rear ends of the freeze plate molds <NUM> provide a spatial frame of reference. For instance, the front of the freeze plate <NUM> that defines the open front ends of the molds <NUM> is spaced apart from the rear of the freeze plate in a forward direction FD (<FIG>), and the back of the freeze plate that extends along the enclosed rear ends of the molds is spaced apart from the front of the freeze plate in a rearward direction RD.

In the illustrated example, the freeze plate <NUM> comprises a pan <NUM> having a back wall <NUM> that defines the back of the freeze plate. Suitably, the pan <NUM> is formed from thermally conductive material such as copper, optionally having one or more surfaces coated with a food-safe material. As is known in the art, the evaporator tubing <NUM> is thermally coupled to the back wall <NUM> of the freeze plate <NUM> for cooling the freeze plate during ice making cycles and warming the freeze plate during harvest cycles.

The pan <NUM> further comprises a perimeter wall <NUM> that extends forward from the back wall <NUM>. The perimeter wall <NUM> includes a top wall portion, a bottom wall portion, a right side wall portion (broadly, a first side wall portion), and a left side wall portion (broadly, a second side wall portion). The side wall portions of the perimeter wall <NUM> define the opposite sides of the freeze plate <NUM>, and the top and bottom wall portions of the perimeter wall define the top and bottom ends of the freeze plate. The perimeter wall <NUM> could be formed from one or more discrete pieces that are joined to the back wall <NUM> or the pan <NUM>, or the entire pan could be formed from a single monolithic piece of material in one or more embodiments. Suitably, the perimeter wall <NUM> is sealed to the back wall <NUM> so that water flowing down the freeze plate <NUM> does not leak through the back of the freeze plate.

A plurality of heightwise and widthwise divider plates <NUM>, <NUM> are secured to the pan to form a lattice of the ice cube molds <NUM>. In an example, each heightwise divider plate <NUM> and each widthwise divider plate <NUM> is formed from a single piece of monolithic material. Each heightwise divider plate <NUM> has a right lateral side surface (broadly, a first lateral side surface) and a left lateral side surface (broadly a second lateral side surface) oriented parallel to the right lateral side surface. Each widthwise divider plate <NUM> has a bottom surface and a top surface oriented parallel to the bottom surface. The heightwise divider plates <NUM> extend from lower ends that are sealingly connected to the bottom wall portion of the perimeter wall <NUM> to upper ends that are sealingly connected to the top wall portion of the perimeter wall. The plurality of widthwise divider plates <NUM> similarly extend from first ends sealingly connected to the right side wall portion of the perimeter wall <NUM> to second ends sealingly connected to the left side wall portion of the perimeter wall.

Generally, the heightwise divider plates <NUM> and the widthwise divider plates <NUM> are interconnected in such a way as to define a plurality of ice molds <NUM> within the perimeter wall <NUM>. For example, each of the heightwise divider plates <NUM> has a plurality of vertically-spaced, forwardly-opening slots <NUM>; each of the widthwise diver plates has a plurality of horizontally-spaced, rearwardly-opening slots <NUM>; and the heightwise and widthwise divider plates are interlocked at the slots <NUM>, <NUM> to form the lattice. Suitably, each widthwise divider plate <NUM> defines a plurality of the molds <NUM> (e.g., at least three molds) immediately above the divider plate and a plurality of the molds (e.g., at least three molds) immediately below the divider plate. Each heightwise divider plate <NUM> likewise defines a plurality of the molds <NUM> (e.g., at least three molds) immediately to one lateral side of the divider plate and a plurality of the molds (e.g., at least three molds) immediately to the opposite lateral side of the divider plate.

Each of the divider plates <NUM>, <NUM> has a front edge and a back edge. The back edges may suitably be sealingly joined to the back wall <NUM> of the freeze plate pan <NUM>. When the freeze plate <NUM> is assembled, the front edges of some or all of the divider plates <NUM>, <NUM> (e.g., at least the widthwise divider plates) lie substantially on a front plane FP (<FIG>) of the freeze plate <NUM>. In one or more examples, the front plane FP is parallel to the back wall <NUM>.

A plurality of the ice molds <NUM> formed in the freeze plate <NUM> are interior ice molds having perimeters defined substantially entirely by the heightwise and widthwise divider plates <NUM>, <NUM>. Others of the molds <NUM> are perimeter molds having portions of their perimeters formed by the perimeter wall <NUM> of the freeze plate pan <NUM>. Each interior ice mold <NUM> has an upper end defined substantially entirely by the bottom surface of one of the widthwise divider plates <NUM> and a lower end defined substantially entirely by the top surface of an adjacent one of the widthwise divider plates. In addition, each interior mold <NUM> has a left lateral side defined substantially entirely by a right lateral side surface of a heightwise divider plate <NUM> and a right lateral side defined substantially entirely by a left lateral side surface of the adjacent heightwise divider plate.

As shown in <FIG>, each widthwise divider plate <NUM> slopes downward and forward from the back wall <NUM> of the freeze plate <NUM> such that an included angle β between an upper surface of each widthwise divider plate and the back wall is greater than <NUM>°. In one or more examples, the included angle β is at least <NUM>° and less than <NUM>°. It can be seen that the included angle between the top surface of each widthwise divider plate <NUM> and the front plane FP is substantially equal to the included angle β. Further, it can be seen that the included angle between the bottom surface of each horizontal divider plate <NUM> and the back wall <NUM> (and also the included angle between the bottom surface of each horizontal divider plate <NUM> and the front plane FP) is substantially equal to <NUM>° minus β. The top and bottom portions of the perimeter wall <NUM> of the pan are oriented substantially parallel to the widthwise divider plates <NUM> in one or more examples.

A series of threaded studs <NUM> extend outward from the perimeter wall <NUM> at spaced apart locations around the perimeter of the freeze plate <NUM>. As will be explained in further detail below, the threaded studs <NUM> are used to secure the freeze plate <NUM> to an evaporator housing <NUM> that attaches the evaporator assembly <NUM> to the support <NUM>. The studs <NUM> are suitably shaped and arranged to connect the freeze plate <NUM> to the evaporator housing <NUM>, and further to the support <NUM>, such that the back wall <NUM> and front plane FP of the freeze plate slants forward when the freeze plate is installed in the ice maker <NUM>.

Referring to <FIG>, the evaporator housing <NUM> will now be described in greater detail. In general, the evaporator housing <NUM> is configured to support the evaporator tubing <NUM> and the freeze plate <NUM>. As will be explained in further detail below, the water distributor <NUM> is integrated directly into (i.e., forms a part of) the evaporator housing <NUM>. The evaporator housing <NUM> comprises a frame including a bottom piece <NUM>, a top piece <NUM>, and first and second side pieces <NUM> that together extend around the perimeter of the freeze plate <NUM>. Each of the bottom piece <NUM>, the top piece <NUM>, and the opposite side pieces <NUM> is formed from a single, monolithic piece of material (e.g., molded plastic), in one or more embodiments. The inner surfaces of the bottom piece <NUM>, the top piece <NUM>, and the opposite side pieces <NUM> may include a gasket (not shown) to aid in watertight sealing of the evaporator housing. The top piece <NUM> of the evaporator housing <NUM> forms a bottom piece (broadly, a first piece) of the two-piece distributor <NUM> in the illustrated embodiment.

A back wall <NUM> is supported on the assembled frame pieces <NUM>, <NUM>, <NUM>, <NUM> in spaced apart relationship with the back wall <NUM> of the freeze plate <NUM>. As shown in <FIG>, the evaporator housing <NUM> defines an enclosed space <NUM> between the back wall <NUM> of the freeze plate <NUM> and the back wall <NUM> of the housing. In one or more embodiments, two discrete layers <NUM>, <NUM> of insulation fills enclosed space <NUM> and thoroughly insulates the evaporator tubing <NUM>.

The bottom piece <NUM>, the top piece <NUM>, the opposite side pieces <NUM>, and/or the back wall <NUM> may have features that facilitate assembling them together to form the evaporator housing <NUM> in a variety of ways, including snap-fit features, bolts and nuts, etc. For example, each of the frame pieces <NUM>, <NUM>, <NUM> comprises stud openings <NUM> that are arranged to receive the studs <NUM> on the corresponding wall portion of the perimeter wall <NUM> of the freeze plate <NUM>. Some of the stud holes <NUM> are visible in <FIG>. In one or more embodiments, the back wall <NUM> is joined to the assembled frame pieces <NUM>, <NUM>, <NUM> by ultrasonic welding.

Referring to <FIG> and <FIG>, one example of how the housing pieces <NUM>, <NUM>, <NUM> attach to the freeze plate <NUM> is shown in greater detail. Specifically, the top housing piece <NUM> is shown, but it will be understood that the other housing pieces may attach to the freeze plate in a like manner. The top piece <NUM> includes a front section that defines the stud openings <NUM>. In the illustrated embodiment, each stud opening <NUM> comprises a countersunk screw recess that includes an annular shoulder <NUM>. The top piece <NUM> is positioned atop the freeze plate <NUM> such that one stud <NUM> is received in each of the openings <NUM>. In the illustrated embodiment, a gasket <NUM> is located between the top of the freeze plate <NUM> and the bottom of the top piece <NUM> to seal the interface between the two parts. Nuts <NUM> are tightened onto each of the studs <NUM> to attach the top piece <NUM> to the freeze plate <NUM>. Further, because the housing top piece <NUM> forms the bottom piece of the distributor <NUM>, tightening the nuts <NUM> onto the studs also attaches the distributor directly to the freeze plate in the illustrated embodiment. Each nut <NUM> is tightened against the shoulder <NUM> of a respective countersunk recesses <NUM> (broadly, the nuts are tightened directly against the top housing piece <NUM> or bottom distributor piece). In the illustrated embodiment, caps <NUM> are placed over the tops of the countersunk recesses <NUM>. Suitably, the tops of the caps <NUM> are substantially flush with the surface of the piece <NUM> to present a smooth surface to water flowing through the distributor <NUM>.

Referring again to <FIG> and <FIG>, each of the side pieces <NUM> of the evaporator housing <NUM> include pre-formed lower and upper screw openings <NUM>, <NUM> at vertically spaced apart locations. The upper and lower screw openings <NUM>, <NUM> are configured to be positioned in registration with the screw openings <NUM>, <NUM> of a respective side wall portion <NUM>, <NUM> of the support <NUM>. When each side piece <NUM> is secured to the freeze plate <NUM> via the studs <NUM>, the screw openings <NUM>, <NUM> are spaced apart along an imaginary line IL2 oriented substantially parallel to the back wall <NUM> and the front plane FP of the freeze plate <NUM>. Referring to <FIG>, when screws (not shown) secure the evaporator assembly <NUM> to the support no via the aligned lower screw openings <NUM>, <NUM> and the aligned upper screw openings <NUM>, <NUM>, the imaginary line IL2 of the evaporator housing <NUM> is aligned with the forwardly slanted imaginary line IL1 of the support.

Thus, the screw openings <NUM>, <NUM>, <NUM>, <NUM> position the freeze plate <NUM> on the support <NUM> so that the back wall <NUM> and front plane FP are oriented at the forwardly slanted angle α with respect to both the plumb vertical axis VA and the back plane BP of the support <NUM>. In one or more embodiments, the included angle α between the back wall <NUM>/front plane FP and the plumb vertical axis VA/back plane BP is at least about <NUM>°. For example, in an exemplary embodiment, the included angle α is about <NUM>°. Accordingly, the illustrated ice maker <NUM> is configured to mount the freeze plate <NUM> in the enclosure <NUM> so that the back wall <NUM> slants forward. It will be appreciated that, though the one-piece support <NUM> and the side pieces <NUM> of the evaporator housing <NUM> are used to mount the freeze plate <NUM> in the slanted orientation in the illustrated embodiment, other ways of mounting a freeze plate may be used in other embodiments.

It is believed that conventional wisdom in the field of ice makers held that orienting a freeze plate with grid-type divider plates so that the back wall of the freeze plate slants forward would adversely affect the water distribution performance of the ice maker. However, because of the high-quality flow distribution produced by the water distributor <NUM>-achieved, for example, using one or more of the water distribution features described below-water is effectively distributed to the molds <NUM> even though the freeze plate <NUM> is mounted with the back wall <NUM> slanted forward. Further, the slanted freeze plate <NUM> enables the ice maker <NUM> to harvest ice quickly, using gravitational forces. In one or more embodiments, the ice maker <NUM> is configured to execute a harvest cycle by which ice is released from the molds <NUM> of the freeze plate <NUM>, wherein substantially the only forces imparted on the ice during the harvest cycle are gravitational forces. For example, the harvest cycle is executed by actuating the hot gas valve <NUM> to redirect hot refrigerant gas back to the evaporator tubing <NUM>, thereby warming the freeze plate <NUM>. The ice in the molds <NUM> begins to melt and slides forward down the sloping widthwise divider plates <NUM>, off the freeze plate, and into the ice bin <NUM>. In a harvest cycle in which substantially the only forces imparted on the ice are gravitational forces, no mechanical actuators, pressurized air jets, or the like are used to forcibly push the ice off of the freeze plate <NUM>. Rather, the slightly melted ice falls by gravity off of the freeze plate <NUM>.

Referring now to <FIG> and <FIG>, an exemplary embodiment of the distributor <NUM> according to claim <NUM> will now be described. As explained above, the distributor comprises a bottom piece <NUM> that forms a top piece of the evaporator housing <NUM>. The distributor <NUM> further comprises a top piece <NUM> that releasably attaches to the bottom piece <NUM> to form the distributor. While the illustrated distributor <NUM> comprises a two-piece distributor that is integrated directly into the evaporator housing <NUM>, it will be understood that distributors can be formed from other numbers of pieces and attach to the ice maker in other ways in other embodiments. As shown in <FIG>, the distributor <NUM> is mounted on the evaporator assembly <NUM> adjacent the top of the freeze plate <NUM> and has a width WD that extends generally along the width WF of the freeze plate <NUM>. The distributor <NUM> extends widthwise from a right end portion (broadly, first end portion) adjacent the right side of the freeze plate <NUM> to a left end portion (broadly, a second end portion) adjacent the left side of the freeze plate.

The distributor <NUM> has a rear, upstream end portion defining an inlet <NUM> and a front, downstream end portion defining an outlet <NUM>. The downstream end portion extends widthwise adjacent the top-front corner of the freeze plate <NUM>, and the upstream end portion extends widthwise at location spaced apart rearward from the downstream end portion. In the illustrated embodiment, the inlet <NUM> formed by an opening at the upstream end portion of the distributor, and the outlet <NUM> is defined by an exposed lower front edge of the distributor <NUM>. In use, this edge is arranged so that water flows off of the edge onto the top portion of the freeze plate <NUM>. It is contemplated that the inlet and/or outlet could have other configurations in other embodiments.

As shown in <FIG>, the distributor <NUM> defines a distributor flow path FP extending generally forward from the inlet <NUM> to the outlet <NUM>. The distributor <NUM> is generally configured to direct water imparted through the distributor along the distributor flow path FP to discharge the water from the outlet <NUM> such that the water flows from the top portion of the freeze plate <NUM> to the bottom portion generally uniformly along the width WF of the freeze plate. As will be explained in further detail below, the distributor <NUM> includes a number of water distribution features that direct the water flowing along the flow path FP to be distributed generally uniformly along substantially the entire width of the distributor.

Each of the bottom and top pieces <NUM>, <NUM> will now be described in detail before describing how the distributor <NUM> is assembled and used to distribute water over the freeze plate <NUM>.

Referring to <FIG>, the bottom distributor piece <NUM> has a right end wall <NUM> (broadly, a first end wall) at the right end portion of the distributor <NUM>, a left end wall <NUM> (broadly, a second end wall) at the left end portion of the distributor, and a bottom wall <NUM> extending widthwise from the right end wall to the left end wall. Referring to <FIG>, as explained above, the bottom distributor piece <NUM> is directly attached to the freeze plate <NUM>. Further, in the illustrated embodiment, the bottom distributor piece <NUM> is in direct contact with the insulation <NUM> that fills the enclosed space <NUM> between the back wall <NUM> of the freeze plate and the back wall <NUM> of the evaporator housing <NUM>. A front section <NUM> of the bottom wall <NUM> is located generally above the freeze plate <NUM> to mount the distributor piece <NUM> on the freeze plate as described above, and a rear section <NUM> of the bottom wall is located generally above the enclosed space <NUM> to directly contact the insulation <NUM>.

In the illustrated embodiment, the rear section <NUM> includes a rear leg <NUM> extending downward at a rear end portion of the bottom wall and a front leg <NUM> extending downward at a location forwardly spaced from the rear leg. Each of the front and rear legs <NUM>, <NUM> extends widthwise between the right and left end walls <NUM>, <NUM> of the bottom distributor piece <NUM>. The rear leg <NUM> is sealingly engaged with the back wall <NUM> of the evaporator housing <NUM> (e.g., the rear leg is ultrasonically welded to the back wall). The bottom wall <NUM> defines a lower recess <NUM> located between the front and rear legs <NUM>, <NUM>. The lower recess <NUM> extends widthwise between the right and left end walls <NUM>, <NUM> and forms the top of the enclosed space <NUM>. Thus a portion of the insulation <NUM> is received in the recess <NUM> and directly contacts the bottom distributor piece along three sides defining the recess. This is thought to thermal losses between the distributor and evaporator.

Referring to <FIG>, each end wall <NUM>, <NUM> in the illustrated embodiment comprises an elongate tongue <NUM> formed along an inner surface. Only the left end wall <NUM> is shown in <FIG>, but it will be understood that the right end wall <NUM> has a substantially identical, mirror image tongue <NUM>. The elongate tongues <NUM> extend longitudinally in parallel, generally front-to-back directions. The elongate tongues <NUM> are generally configured to form male fittings that releasably couple the bottom distributor piece <NUM> to the top distributor piece <NUM> without the use of separate fasteners. Each elongate tongue <NUM> has a front end portion and a rear end portion spaced apart longitudinally from the front end portion. Between the front end portion and the rear end portion, each tongue comprises a slight depression <NUM>.

Referring to <FIG> and <FIG>, the bottom wall <NUM> extends generally forward from a rear, upstream end portion to a front, downstream end portion. A rear wall <NUM> extends upward from the upstream end portion of the bottom wall <NUM>. The inlet opening <NUM> is formed in the rear wall <NUM>. In the illustrated embodiment, the inlet opening <NUM> is generally centered on the rear wall <NUM> at a spaced apart location between the end walls <NUM>, <NUM>. Thus, broadly speaking, the inlet opening <NUM> through which water is directed into the interior of the distributor <NUM> is spaced apart widthwise between the first end portion and the second end portion of the distributor. During use, the distributor <NUM> is configured to direct the water to flow from the inlet opening <NUM> along the bottom wall <NUM> in a generally forward direction FD from the upstream end portion of the bottom wall to the downstream end portion.

An integral inlet tube <NUM> protrudes rearward from the rear wall <NUM> and fluidly communicates through the rear wall via the inlet opening <NUM>. The tube <NUM> slopes downward and rearward as it extends away from the rear wall <NUM>. The inlet tube <NUM> is configured to be coupled to the ice maker's water line <NUM> (<FIG>). Accordingly, when ice is being made, the pump <NUM> pumps water from the sump <NUM> through the water line <NUM> and into the distributor <NUM> via the integral inlet tube <NUM>. When ice is not being made, residual water in the distributor <NUM> can drain through the inlet tube <NUM>, down the water line <NUM>, and into the sump <NUM>.

According to the present invention, the rear section <NUM> of the bottom wall <NUM> slopes downward and rearward along substantially the entire width of the bottom wall. Conversely, the front section <NUM> of the bottom wall <NUM> slopes downward and forward along substantially the entire width. The front section <NUM> thus forms a runoff section along which water flows forward and downward toward the downstream end portion of the bottom wall <NUM>. Between the sloping rear section <NUM> and the sloping front section <NUM> the bottom wall comprises a middle section that includes a widthwise groove <NUM>. The widthwise groove is configured to sealingly receive a portion of the top distributor piece <NUM> when the top distributor piece is coupled to the bottom distributor piece <NUM>. In one or more embodiments, the groove <NUM> is convex in the widthwise direction (see FIG. An apex of the bottom wall <NUM> is located immediately upstream of the widthwise groove <NUM>. The rear section <NUM> of the bottom wall slopes downward from the apex to the rear wall <NUM>. As shown in <FIG>, the rear section <NUM> of the bottom wall <NUM> includes a ramp surface <NUM> that defines the apex and a rearmost (or upstream-most) surface portion <NUM> (broadly, an upstream segment). The ramp surface <NUM> and the rearmost surface portion <NUM> extend widthwise from the right end wall <NUM> to the left end wall <NUM>. The ramp surface <NUM> slopes upward in the generally forward direction and downward in the generally rearward direction. The rearmost surface portion <NUM> slopes upward in the generally forward direction more gradually than the ramp surface <NUM>. The rearmost surface portion <NUM> is oriented at an angle of less than <NUM>° with respect to the ramp surface <NUM> such that the rearmost surface portion slopes downward in the generally rearward direction at a more gradual angle than the ramp surface in the illustrated embodiment.

The bottom wall <NUM> is configured to passively drain water from the distributor <NUM> when the ice maker <NUM> stops making ice. Whenever the ice maker <NUM> stops making ice, residual water in the front portion of the distributor <NUM> flows forward along the sloping front section <NUM> (runoff section) of the bottom wall <NUM> and drains off of the outlet <NUM> onto the freeze plate <NUM>. Similarly, residual water in the rear portion of the distributor <NUM> flows rearward along the sloping rear section <NUM> and drains through the inlet opening <NUM> into the inlet tube <NUM>. The water directed forward flows downward along freeze plate <NUM> and then flows off the freeze plate into the sump <NUM>. The water directed rearward flows downward through the water line <NUM> into the sump <NUM>. Thus, the distributor <NUM> is configured to direct substantially all residual water into the sump <NUM> when the ice maker <NUM> is not making ice. Further, in one or more embodiments, the sump <NUM> is configured to drain substantially all of the water received therein through the discharge line <NUM> when the ice maker <NUM> is not in use. As can be seen, the shape of the bottom wall <NUM> of the distributor <NUM> facilitates total passive draining of the ice maker <NUM> when ice is not being made.

Referring to <FIG>, a lateral diverter wall <NUM> extends upward from the bottom wall <NUM> along the rearmost surface portion <NUM>. The lateral diverter wall <NUM> is spaced apart between the rear wall <NUM> and the ramp surface <NUM>. The lateral diverter wall <NUM> extends upward from the bottom wall <NUM> to a top edge that is spaced apart below the top of the assembled distributor <NUM> (see <FIG>). The diverter wall <NUM> extends widthwise from a right end portion (broadly, a first end portion) spaced apart from the right end wall <NUM> to a left end portion (broadly, a second end portion) spaced apart from the left end wall <NUM>. The lateral diverter wall <NUM> is positioned in front of the inlet opening <NUM>. As water flows into the distributor <NUM> through the inlet opening, the lateral diverter wall <NUM> is configured to divert at least some of the water laterally outward, forcing the water to flow around the left and right ends of the lateral diverter wall.

Referring to <FIG> and <FIG>, the downstream end portion of the bottom wall <NUM> defines a downwardly curving surface tension curve <NUM> that extends widthwise from the right end wall <NUM> to the left end wall <NUM>. The downwardly curving surface tension curve <NUM> is configured so that surface tension causes the water flowing along the bottom wall <NUM> to adhere to the curve and be directed downward by the curve toward the top end portion of the freeze plate <NUM>. In one or more embodiments, the surface tension curve <NUM> is at least partially defined by a radius R of at least <NUM>. In certain embodiments, the surface tension curve <NUM> is defined by a radius of less than <NUM>. In one or more embodiments, the surface tension curve <NUM> is defined by a radius in an inclusive range of from <NUM> to <NUM>. In an exemplary embodiment, the surface tension curve <NUM> is defined by a radius of <NUM>.

The bottom wall <NUM> further comprises a waterfall surface <NUM> extending generally downward from the surface tension curve <NUM> to a bottom edge that defines the outlet <NUM> of the distributor <NUM>. The waterfall surface <NUM> extends widthwise from the right end wall <NUM> to the left end wall <NUM>. The waterfall surface <NUM> generally is configured so that surface tension causes the water imparted through the distributor <NUM> to adhere to the waterfall surface and flow downward along the waterfall surface onto the top end portion of the freeze plate <NUM>. In one or more embodiments, the waterfall surface <NUM> slants forward in the ice maker <NUM> such that the waterfall surface is oriented generally parallel to the back wall <NUM> (and front plane FP) of the forwardly slanting freeze plate <NUM>.

Referring to <FIG>, the top distributor piece <NUM> has a right end wall <NUM> (broadly, a first end wall) at the right end portion of the distributor <NUM> and a left end wall <NUM> (broadly, a second end wall) at the left end portion of the distributor. The width of the top distributor piece <NUM> is slightly less than the width of the bottom distributor piece <NUM> such that the top distributor piece is configured to nest between the end walls <NUM>, <NUM> of the bottom distributor piece.

Referring to <FIG>, each end wall <NUM>, <NUM> in the illustrated embodiment comprises an elongate groove <NUM> along an outer surface. Only the left end wall <NUM> is shown in <FIG>, but it will be understood that the right end wall <NUM> has a substantially identical, mirror image groove <NUM>. Generally, the elongate grooves <NUM> are configured to form complementary female fittings that mate with the male fittings formed by the elongate tongues <NUM> to releasably couple the top distributor piece <NUM> to the bottom distributor piece <NUM> without the use of separate fasteners. The elongate grooves <NUM> are generally parallel, extending longitudinally in a generally front-to back direction. The rear end portion of each elongate groove <NUM> defines a flared opening through which a respective elongate tongue <NUM> can pass into the groove. Each end wall further defines a protuberance <NUM> that protrudes into the groove at a location spaced apart between the front and rear ends of the groove <NUM>.

Referring again to <FIG>, the top distributor piece <NUM> comprises a top wall <NUM> that extends widthwise from the right end wall <NUM> to the left end wall <NUM>. The top wall <NUM> extends generally forward from a rear edge margin. A front wall <NUM> extends generally downward from a front end portion of the top wall to a free bottom edge margin. Two handle portions <NUM> extend forward from the front wall <NUM> in the illustrated embodiment.

As shown in <FIG>, the top distributor piece <NUM> further comprises a weir <NUM> that extends downward from the top wall <NUM> at a location spaced apart between the rear edge margin and the front wall <NUM>. The weir <NUM> extends widthwise from the right end wall <NUM> to the left end wall <NUM> and has a free bottom edge margin that is configured to be received in the widthwise groove <NUM> of the bottom distributor piece <NUM>. As shown in <FIG>, the bottom edge margin of the weir <NUM> is convex in the widthwise direction. The weir <NUM> defines a plurality of openings <NUM> at spaced apart locations along the width WD of the distributor <NUM>. A bottom portion of the weir <NUM> below the openings <NUM> is configured to hold back water until the water level reaches the bottom of the openings. The openings <NUM> are configured so that water is passable through the openings as it is imparted through the distributor <NUM>. Adjacent openings are separated by portions of the weir <NUM>, such that the weir is configured to form a segmented weir that allows water to cross at spaced apart segments along the width WD of the distributor <NUM> (through the openings).

Referring to <FIG>, to assemble the distributor <NUM>, the top distributor piece <NUM> is aligned in the widthwise direction with the space between the end walls <NUM>, <NUM> of the bottom distributor piece <NUM>. Then the top piece <NUM> is moved in the rearward direction RD into the space between the rear walls <NUM>, <NUM>, such that the elongate tongues <NUM> of the bottom piece are slidably received in the elongate grooves <NUM> of the top piece.

As seen in <FIG>, the evaporator assembly <NUM> is suitably arranged in the interior of the ice maker enclosure <NUM> so that the top piece <NUM> can be installed/removed through an access opening <NUM> such as the doorway of the cabinet <NUM>. In the illustrated embodiment, the doorway <NUM> is spaced apart from the front of the evaporator assembly <NUM> in the forward direction FD. Further, the front opening <NUM> in the support <NUM> is located between the front of the evaporator assembly <NUM> and the doorway <NUM>. Thus, the top distributor piece <NUM> can be installed by moving the piece through the doorway <NUM> and the opening <NUM> in the rearward direction RD. The top distributor piece <NUM> is removed by moving the piece through the opening <NUM> and the doorway <NUM> in the forward direction FD.

Each tongue <NUM> is configured to be slidably received in the respective groove <NUM> as the top distributor piece <NUM> moves toward the bottom distributor piece <NUM> in the rearward direction RD. That is, the parallel longitudinal orientations of the tongues <NUM> and grooves <NUM> facilitate coupling the top distributor piece <NUM> to the bottom distributor piece <NUM> simply by moving the top distributor piece in the rearward direction RD. Thus, the complementary fittings formed by the tongues <NUM> and grooves <NUM> are configured to be engaged by movement of the top distributor piece <NUM> inward into the interior of the enclosure <NUM> from the doorway <NUM>. Further, the complementary fittings <NUM>, <NUM> are configured to be disengaged simply by urging the top distributor piece <NUM> away from the bottom distributor piece <NUM> in the forward direction FD, toward the doorway <NUM>. When maintenance or repair of the distributor <NUM> is required, a technician merely opens the door <NUM> (<FIG>), grips the handles <NUM>, and pulls the top distributor piece <NUM> outward in the forward direction FD through the doorway <NUM>. To replace the top distributor piece <NUM>, the technician inserts the piece through the doorway <NUM>, aligns the open ends of the grooves <NUM> with the tongues <NUM>, and pushes the top piece rearward. The tongues <NUM> are then slidably received in the grooves <NUM>, and the complementary fittings thereby couple the top distributor piece <NUM> to the bottom distributor piece <NUM> without using any additional fasters such as screws or rivets.

Though the illustrated embodiment uses the bottom distributor piece's elongate tongues <NUM> as male fittings and the top distributor piece's elongate grooves <NUM> as complementary female fittings, other forms or arrangements of complementary integral fittings can be utilized to releasably couple one distributor piece to another in one or more embodiments. For example, it is expressly contemplated that in certain embodiments one or more male fittings could be formed on the top distributor piece and one or more complementary female fittings could be formed on the bottom distributor piece. It is further contemplated that the fittings could be formed at alternative or additional locations other than the end portions of the distributor.

Referring to <FIG>, each pair of complementary fittings comprises a detent configured to keep the respective tongue <NUM> at a coupling position along the respective groove <NUM>. More specifically, the protuberances <NUM> formed in the grooves <NUM> are configured to be received in the depressions <NUM> of the tongues <NUM> to provide a detent when the complementary fittings are at the coupling position. The detent resists inadvertent removal of the top distributor piece <NUM> from the bottom distributor piece <NUM> and provides a tactile snap when the tongue <NUM> slides along the groove <NUM> to the coupling position. It will be appreciated that the detent can be formed in other ways in one or more embodiments.

Referring to <FIG> and <FIG>, as the top distributor piece <NUM> slides in the rearward direction RD to couple the distributor pieces together, the bottom edge margin of the weir <NUM> slides along the downstream (front) section <NUM> of the bottom wall <NUM>. When the top distributor piece <NUM> reaches the coupling position, the bottom edge margin of the weir <NUM> is received in the groove <NUM>. In one or more embodiments, placing the weir <NUM> in the groove <NUM> requires pushing the top piece <NUM> rearward past a slight interference with the bottom piece <NUM>. When the bottom edge margin of the weir <NUM> is received in the groove <NUM>, the weir sealingly engages the bottom wall <NUM> such that water flowing along the distributor flow path FP is inhibited from flowing through an interface between the bottom edge margin of the weir and the bottom wall and is instead directed to flow across the weir through the plurality of openings <NUM>.

The weir <NUM> extends widthwise along a middle section of the assembled distributor <NUM>, at a location spaced apart between the front wall <NUM> and the rear wall <NUM>. The only couplings between the top distributor piece <NUM> and the bottom distributor piece <NUM> at this middle section of the distributor <NUM> are the tongue-and-groove connections at the left and right end portions of the distributor. Thus, in the illustrated embodiment, the middle section of the distributor <NUM> includes couplings at the first and second end portions of the distributor that restrain upward movement of the top distributor piece <NUM> with respect to the bottom distributor piece <NUM>, but the distributor is substantially free of restraints against upward movement of the top distributor piece relative the bottom distributor piece along the middle section of the distributor at locations between these couplings. However, because the bottom edge margin of the weir <NUM> is convex and the groove <NUM> is correspondingly concave in the widthwise direction (<FIG>), even as the distributor pieces <NUM>, <NUM> flex and deform during use, the seal between the weir and the bottom wall <NUM> is maintained and water is reliably directed to flow through of openings <NUM>, instead of downward through the interface between the weir and the bottom wall.

Referring to <FIG>, the distributor <NUM> is configured to direct water to flow from the inlet <NUM> to the outlet <NUM> such that the water flows along the flow path FP between the bottom and top walls <NUM>, <NUM> and then is directed downward along the surface tension curve <NUM> and the water fall surface <NUM> onto the top portion of the freeze plate <NUM>. Initially, the water flows generally in the forward direction from the inlet tube <NUM> through the inlet opening <NUM> in the rear wall <NUM>. The water then encounters the lateral diverter wall <NUM>. The lateral diverter wall <NUM> diverts at least some of the water laterally outward, such that the water continues forward through the widthwise gaps between the end portions of the lateral diverter wall and the end portions of the distributor <NUM>.

After flowing past the lateral diverter wall <NUM>, the water encounters the ramp surface <NUM> and the segmented weir <NUM>. The ramp surface <NUM> is immediately upstream of the weir <NUM> such that the water flowing along the bottom wall <NUM> of the distributor <NUM> must flow upward along the ramp surface before flowing across the weir. The weir <NUM> is configured so that the openings <NUM> are spaced apart above the bottom wall <NUM> (e.g., the bottom edges of the openings are spaced apart above the apex of the ramp surface <NUM>). Thus, in the illustrated embodiment, the water must flow upward along the ramp surface <NUM>, and upward along a portion of the height of the weir <NUM> before it can flow through the openings <NUM> across the weir. In one or more embodiments, the weir <NUM> is configured so that the portion of the distributor <NUM> upstream of the weir backfills with water to a level that generally corresponds with the height of the bottom edges of the openings <NUM> before the water begins to spill over the weir through the openings. In certain embodiments, the ramp surface <NUM> can direct at least some of the water flowing in the forward direction FD along the ramp surface to flow through the openings <NUM> before the upstream portion of the distributor <NUM> fills with water to a level that corresponds with the height of the bottom edges of the openings. After flowing across the weir <NUM>, the water drops downward onto the sloped front runoff section <NUM> of the bottom wall <NUM> and then flows downward and forward.

As can be seen, the upper rear edge of the front runoff section <NUM> is spaced apart below the openings <NUM> by a substantially greater distance than the apex of the ramp surface <NUM>. Thus, the water falls a relatively great distance from the segmented weir <NUM> onto the front runoff section <NUM>, which may create turbulence on impact, enhancing the distribution of water in the distributor <NUM>. In one or more embodiments, the vertical distance between the bottom edges of the openings <NUM> and the upper rear edge of the front runoff section <NUM> is at least <NUM>; e.g., at least <NUM>, e.g., at least <NUM>; e.g., about <NUM> to <NUM>.

Referring to <FIG>, in the assembled distributor <NUM>, the front wall <NUM> of the top distributor piece <NUM> forms an overhanging front wall that overhangs the bottom wall <NUM>. The bottom edge margin of the front wall <NUM> is spaced apart above the forwardly/downwardly sloping front runoff section <NUM> of the bottom wall <NUM> such that a flow restriction <NUM> is defined between the runoff section and the overhanging front wall. The flow restriction <NUM> comprises a gap (e.g., a continuous gap) that extends widthwise between the first end portion and the second end portion of the distributor <NUM>. In general, the flow restriction <NUM> is configured to restrict a rate at which water flows through the flow restriction toward the outlet <NUM>. In one or more embodiments, the flow restriction <NUM> has a height extending vertically from the runoff section <NUM> to the bottom of the front wall <NUM> of less than <NUM>, e.g., less than <NUM>; e.g., less than <NUM>; e.g., about <NUM> to <NUM>.

The water flowing forward along the front section <NUM> reaches the flow restriction <NUM>, and the flow restriction arrests or slows the flow of water. In one or more embodiments, the overhanging front wall <NUM> acts as a kind of inverted weir. The flow restriction <NUM> slows the flow of water to a point at which water begins to slightly backfill the front portion of the distributor <NUM>. This creates a small reservoir of water behind the flow restriction <NUM>. A metered amount of water flows continuously from this back-filled reservoir through the flow restriction <NUM> along substantially the entire width WD of the distributor <NUM>.

The surface tension curve <NUM>-and more broadly the downstream end portion of the bottom wall <NUM>-is forwardly proud of the overhanging front wall <NUM> and the flow restriction <NUM>. After the water flows (e.g., is metered) through the flow restriction <NUM>, the water adheres to the downwardly curving surface tension curve <NUM> as it flows generally forward. The surface tension curve <NUM> directs the water downward onto the waterfall surface <NUM>. The water adheres to the waterfall surface <NUM> and flows downward along it. Finally the water is discharged from the outlet edge <NUM> of the waterfall surface <NUM> onto the top end portion of the freeze plate <NUM>.

Because of water distribution features such as one or more of the lateral diverter wall <NUM>, the ramp surface <NUM>, the segmented weir <NUM>, the flow restriction <NUM>, the surface tension curve <NUM>, and the waterfall surface <NUM>, water is discharged from the outlet <NUM> at a substantially uniform flow rate along the width WD of the distributor <NUM>. The distributor <NUM> thus directs water imparted through the distributor to flow downward along the front of the freeze plate <NUM> generally uniformly along the width WF of the freeze plate during an ice making cycle. Moreover, the distributor <NUM> controls the dynamics of the flowing water so that the water generally adheres to the surfaces of the front of the freeze plate <NUM> as it flows downward. Thus, the distributor <NUM> enables ice to form at a generally uniform rate along the height HF and width WF of the freeze plate <NUM>.

During use the ice maker <NUM> alternates between ice making cycles and harvest cycles. During each ice making cycle, the refrigeration system is operated to cool the freeze plate <NUM>. At the same time, the pump <NUM> imparts water from the sump <NUM> through the water line <NUM> and further through the distributor <NUM>. The distributor <NUM> distributes water along the top portion of the freeze plate <NUM> which freezes into ice in the molds <NUM> at a generally uniform rate along the height HF and width WF of the freeze plate <NUM>. When the ice reaches a thickness that is suitable for harvesting, the pump <NUM> is turned off and the hot gas valve <NUM> redirects hot refrigerant gas to the evaporator tubing <NUM>. The hot gas warms the freeze plate <NUM>, causing the ice to melt. The melting ice falls by gravity from the forwardly slanted freeze plate <NUM> into the bin <NUM>. When harvest is complete, the pump <NUM> can be reactivated to begin a new ice making cycle. But if additional ice is not required, the discharge valve <NUM> is opened. Residual water in the distributor <NUM> drains into the sump <NUM> as described above, and the water from the sump drains through the discharge line <NUM>. The discharge valve <NUM> can be closed when the water level sensor <NUM> detects that the sump <NUM> is empty. If repair or maintenance of the distributor <NUM> should ever be required, a technician can simply open the door <NUM> to the enclosure and pull out the top piece <NUM> as described above. No fasteners are used when removing and replacing the top distributor piece <NUM>.

When introducing elements of the present invention or the preferred embodiment(s) thereof, the articles "a", "an", "the" and "said" are intended to mean that there are one or more of the elements.

In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.

Claim 1:
A distributor (<NUM>) for receiving water imparted through the distributor and directing the water to flow along a freeze plate (<NUM>) of an ice maker (<NUM>) so that the water forms into ice on the freeze plate, the distributor comprising:
a distributor piece (<NUM>) formed from a single piece of monolithic material;
the distributor piece comprising a bottom wall (<NUM>) defining a portion of a flow path along which the distributor directs water to flow through the distributor and extending forward from a rear wall (<NUM>) to a front end portion adjacent a downstream end of the distributor;
the distributor further comprising:
the rear wall adjacent an upstream end of the distributor; and
a tube (<NUM>) protruding rearward from the rear wall, the rear wall having an opening (<NUM>) immediately above the bottom wall through which the tube fluidly communicates with the distributor;
wherein the bottom wall comprises a rear section (<NUM>) that slopes downward to the rear wall and a front section (<NUM>) that slopes downward to the front end portion.