CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority U.S. Provisional Patent Application No. 62/372,817, filed August 10, 2016, entitled "Dry Harvesting for Ice Cube Makers", U.S. Provisional Patent Application No. 62/446,902, filed January 17, 2017, entitled "Dry Harvesting Components for Ice Machines", and U.S. Provisional Patent Application No. 62/504,157, filed May 10, 2017, entitled "Ice Supporting Plate for Dry Harvesting Ice Machines", which are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The invention relates to the field of ice making machines.

BACKGROUND

Ice making machines may make ice in different forms, such as cubes, tubes, plates, flakes, and/or the like. Many machines operate in batches and use wet ejecting to remove the ice after being formed on an evaporation surface. During wet ejecting, the evaporation surface is heated, possibly using the refrigeration elements operated in reverse, and the ice adjacent to the surface melts to release the ice slab, plate, batch, tube, and/or the like. The ejected ice drops into a collection bin, and ice tube machines will chop the long tubes of ice into smaller pieces. Ice cube machines may be typically used in restaurants, hotels, and/or the like, while ice tube and plate machines may be used for commercial ice production, such as bags of ice distributed to supermarket chains, ice for fisheries, and/or the like.

The foregoing examples of the related art and limitations related therewith 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 figures.

SUMMARY

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. There is provided, in accordance with an embodiment, an ice machine, comprising a pressure source configured to provide a gas at a pressure above ambient pressure and an evaporator grid. The evaporator grid comprises an evaporator back board (e.g. evaporator back board, can be made from high conductive polymer, combination of metal and polymer, metal, etc.) and an elastic substrate disposed over the evaporator back board, configured to elastically contract in thickness towards the evaporator back board by at least 10 micrometers. The evaporator grid comprises a gas valve in fluid communication with the pressure source. The gas valve is configured to initiate separation between the elastic substrate and an ice block that is formed in the evaporator grid. The ice machine comprises one or more controllers configured to inject the gas into a space formed by the separation, where the gas has a pressure above ambient pressure.

In some embodiments, the evaporator grid further comprises an ice seal mechanism along the periphery of the evaporator back board, where the ice seal mechanism is configured to prevent escape of the gas until the ice is mostly detached from the elastic substrate, and configured for ejecting the ice into a dispenser thereafter.

In some embodiments, ice seal mechanism comprises one or more of: an angled metallic surface, where the angled metallic surface is substantially rigid; a groove; a rigid area of the elastic substrate; a heating element; a mechanical lever; a compressible cushion disposed within a groove; and a removeable seal frame.

In some embodiments, the gas valve comprises a gas outlet notch and one or more of: an expandable cushion in mechanical communication with the gas outlet notch; a central pin configured to seal the gas outlet notch when ice is formed in the evaporator grid; a piston connected to one edge of the gas outlet notch, and configured to slide away from the gas outlet notch when the gas is applied; and a central pin configured to slide out of the gas valve towards the ice block and assist in ejecting the ice block.

In some embodiments, the evaporator back board comprises a plurality of voids for receiving at least part of the elastic substrate when the elastic substrate is elastically contracted.

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

In some embodiments, the ice block comprises a plurality of ice cubes and the ice machine is an ice cube machine.

In some embodiments, the ice block comprises one or more ice tubes, the evaporator grid is an array of evaporator tubes, and the ice machine is a tube ice machine. In some embodiments, the ice block comprises one or more ice plates, and the ice machine is a plate ice machine.

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

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

In some embodiments, the ice machine further comprises a rigid ice support plate opposing the elastic substrate for preventing a bending of the ice slab during ejection.

In some embodiments, the rigid ice support plate comprises elevated ridges.

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

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

There is provided, in accordance with an embodiment, a method for ejecting ice from an ice machine comprising using one or more controller configured for commanding the actions of inserting a gas into a gas valve connected to an evaporator back board of an evaporator grid, where the gas is at a pressure least 0.1 bar above ambient pressure. The controller(s) are configured for an action of initiating separation between an ice block and an elastic substrate in a region surrounding the gas valve by mechanical manipulation of an outlet notch of the gas valve, where the elastic substrate is disposed over the evaporator back board. The controller(s) are configured for an action of expanding separation between the ice block and the elastic substrate by contraction of the elastic substrate towards the evaporator back board by at least 10 micrometers until most of the ice block is separated from the elastic substrate.

In some embodiments, the method further comprises an action of applying a force directed at least in part towards elastic substrate during the separation of the ice block, and further comprises an action of releasing the force during the ejection of the ice block. In some embodiments, the method further comprises an action of ejecting the ice block from the evaporator grid by: breaking a seal between the ice block and evaporator grid surrounding the periphery of the elastic substrate, and applying an ejection force on the ice block in the direction of an ice dispenser. In some embodiments, the seal is created during formation of the ice block on an angled metallic surface, where the angled metallic surface is substantially rigid.

In some embodiments, the seal is created during formation of the ice block in a groove.

In some embodiments, the breaking of the seal comprises one or more actions from: activating a heating element; operating a mechanical lever; expanding a compressible cushion disposed within a groove; and moving a removeable seal frame.

In some embodiments, the ejection force is applied by the action of sliding a central pin out of the gas valve towards the ice block to assist in ejecting the ice block.

In some embodiments, the initiating separation comprises an action of a release of the gas from the outlet notch and one or more actions from: expanding a valve cushion in mechanical communication with the gas outlet notch; moving a central pin configured to seal the gas outlet notch when ice is formed in the evaporator grid; sliding a piston connected to one edge of the gas outlet notch in a direction away from the gas outlet notch when the gas is applied; heating the ice surrounding the valve; and leaking a low- pressure gas into the water prior to ice formation.

In some embodiments, the contraction of the elastic substrate is assisted be at least part of the elastic substrate compressing into a plurality of voids in the evaporator back board.

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

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

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

In some embodiments, the contraction of the elastic substrate towards the evaporator back board is by at least 10 micrometers.

In some embodiments, the contraction of the elastic substrate towards the evaporator back board continues until most of the ice block is separated from the elastic substrate. In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the figures and by study of the following detailed description. BRIEF DESCRIPTION OF THE FIGURES

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

FIG. 1 shows a schematic illustration of an ice machine with dry harvesting;

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

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

FIG. 4 shows a cross section diagram of an evaporator grid for dry harvesting of ice;

FIG. 5 shows cross section diagrams of a compressed gas valve for dry harvesting of ice;

FIG. 6 shows a cross section diagram of measurements of a compressed gas valve for dry harvesting of ice;

FIG. 7 shows cross section diagrams of compressed gas valves for dry harvesting of ice during a separation stage;

FIG. 8 shows cross section diagrams of a gas bubble generated from a valve for dry harvesting of ice;

FIG. 9 shows cross section diagrams of a gas bubble generated from a second valve for dry harvesting of ice;

FIG. 10 shows cross section diagrams of grid voids for dry harvesting of ice; FIG. 11 shows cross section diagrams of flexible regions of an elastic substrate for dry harvesting of ice;

FIG. 12 shows cross section diagrams of an ice plate seal for dry harvesting of ice; FIG. 13 shows a cross section diagram of a separated ice plate seal for dry harvesting of ice;

FIG. 14 shows a cross section diagram of a mechanically separated ice plate seal for dry harvesting of ice; FIG. 15 shows a cross section diagram of a pressure activated ice plate seal for dry harvesting of ice;

FIG. 16 shows a cross section diagram of a valve with an ejection pin for dry harvesting of ice;

FIG. 17 shows cross section diagrams of a tube ice machine with dry harvesting of ice;

FIG. 18 shows lateral cross section diagrams of a tube ice machine with dry harvesting of ice;

FIG. 19 shows lateral cross section diagrams of an ice tube separation from an evaporator grid during dry harvesting of ice;

FIG. 20 shows a lateral cross section diagram of an ice tube ejection from an evaporator grid during dry harvesting of ice;

FIG. 21 shows cross section diagrams of alternative ice tube ejection during dry harvesting of ice;

FIG. 22 shows a schematic illustration of an embodiment for dry ejection with a splash curtain;

FIG. 23 shows a schematic illustration of an embodiment for dry ejection with a splash curtain before ice formation;

FIG. 24 shows a schematic illustration of an embodiment for dry ejection with a splash curtain after ice formation;

FIG. 25 shows a schematic illustration of an embodiment for dry ejection with a splash curtain during ice ejection; and

FIG. 26 shows a schematic illustration of an embodiment for dry ejection with a splash curtain after ice ejection.

DETAILED DESCRIPTION

Described herein are methods and devices for dry ejection of ice blocks, slabs, tubes, and/or the like in ice machines. Dry ejection of ice blocks may be performed with a valve configured to inject compressed fluid in between the ice and an evaporator grid, where the evaporator grid comprises a back board (i.e. with high thermal conductivity) and an elastic substrate. The fluid may be the ambient gas, such as air, a processed gas, a liquid, such as water, and/or the like, and the term gas and/or air as used herein may mean any fluid suitable and/or capable of separating between the ice plate and the grid. For example, this gas has a lower density than the ambient atmosphere. The valve may also be configured to be at least partially flexible and/or elastic and initiate a crack between the ice and the grid when the compressed gas is applied to the valve. The grid may be covered with one or more elastic substrate materials, that may allow the substrate to move away from the ice, such as contract in thickness, by the motion of the compressed gas. Special regions of flexibility are configured around corners so that the compressed gas passes to most locations between the ice and the grid.

A special region around the perimeter of the ice grid may form a seal for the compressed gas to remain between the ice and grid without leaking out from the edges of the grid. For example, an ice gasket groove fills with water that freezes to ice thus forming a seal. Once the ice and grid are mostly detached, the ice is ejected by releasing the seal around the perimeter of the ice. These stages of the dry ejecting may be referred to as a separation initiation, an ice detachment, and an ice ejection. Dry ejection may be used with ice cube machines with horizontal or vertical evaporator, ice tube machines, ice plate machines, and/or the like.

As used herein, the term "valve" means an orifice in the evaporator grid for injecting compressed air between the grid and one or more blocks of ice formed on the grid. The valve may be a simple hole, a slit, a hole with some flexible parts to initiate separation between the ice block(s) and the grid, a hole with a mechanical element for facilitating the ejection of the ice after separation, and/or the like. The valve may operate under positive or negative pressure relative to the ambient pressure. For example, the valve may have a slit that prevents water from entering the valve and forming ice. A flexible region of the valve at least in part surrounding the slit, will deform by the application of a compressed gas on within the valve so that at least some of the flexible region will separate from the ice block and allow the compressed gas to pass between the ice block and the elastic substrate. Optionally, flexible region and/or components within the valve may assist in the initial separation of the ice from the elastic substrate.

For the grid to have an elastic substrate while retaining good thermal conductivity to form the ice, the grid may comprise two or more different materials, such as (i) a base material with good thermal conductivity, and (ii) an ice forming substrate. The base material of the grid may be a material of high thermal conductivity, for example between 2 and 400 watt-meter per degree kelvin (Wm/K), that may be very rigid, such as metal alloys comprising copper, zinc, aluminium, and/or the like. An elastic heat conducting substrate made of flexible heat conducting material covers the base material, such as an evaporator back board, so that the ice is formed on the elastic substrate. For example, the elastic substrate, has a Shore hardness (OO scale) with values between 10 and 90, such as a gel material, paste, a rubber material, a synthetic viscoelastic urethane polymer (Sorbothane®) material, and/or the like, and may be composed from number of materials with different Shore hardness, as well. Examples for elastic substrate are the thermal interface materials (TIMs) consists of a polymerizable matrix and large volume fractions of thermally conductive filler. Typical matrix materials are epoxies, silicones, urethanes, and acrylates, solvent-based systems, hot-melt adhesives, and/or the like. Aluminium oxide, boron nitride, zinc oxide, aluminium 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 so that the elastic substrate, which may be an incompressible material, can expand into the voids when the compressed gas passes between the ice and the substrate. Thereby, the elastic substrate may contract in thickness by at least 10 micrometers, and thus separate from the ice. For example, the elastic material contracts between 5 micrometers and 5 millimeters. Optionally, the elastic substrate comprises gas voids, such as air bubbles, micro bubbles, and/or the like, that contract during the passing of the compressed gas and allow the elastic flexibility of the substrate. The elastic heat conduction substrate may further comprise a thin outer layer of high-deflection, stiff, flexible material, such as a food-safe metal, on the side where the ice blocks are formed to provide mechanical support for the flexible substrate. The stiff outer layer may help to:

• return the elastic heat conduction substrate to its original size and shape when the gas pressure is removed,

• durability for the grid, • food and drug administration (FDA) compliance,

• hydrophobic properties,

• hydrophilic properties,

• and/or the like.

For example, hard steel, hard stainless steel, spring steel, metal alloys comprising phosphorus bronze, nickel, cobalt, brass and/or the like, may be used as a stiff outer layer of the elastic substrate.

The outer layer may include of specific food safe material coating, having for example, a 'hydrophobic texture' or a 'hydrophilic texture' , composed from millimeter (mm), micrometer (micron), or sub-micron size elements, which may be periodic, quasi- periodic or disorderly. For example, geometric structures may be composed of pillars, conical shapes, spherical shapes, a series of geometric structures, combinations of shapes, protrusions, niches, and/or the like. Textures may be made using combinations of hot embossing techniques, imprint techniques, etching process, layer by layer depositions, and/or the like. These textures may serve as micro air tunnels, during motion of the compressed gas.

The elastic substrate may be connected to the grid and/or evaporator by gluing, adhesives, compression springs, compression bolts, bolts, rivets, compression rivets, springs, spot welding, ultrasonic welding, cold welding, and/or the like. The outer layer may be manufactured and/or connected to the elastic substrate, either entirely or in parts, by stamping, folded, pressed, milled, deep drawing, with a polymer by injection overmolding, and/or the like.

The stage of separation initiation is the formation of a crack between the ice and grid around the valve, and the valve can take an active of passive part in the crack formation, such as the initial separation between the ice and the substrate. The stage of ice detachment is facilitated by the elastic substrate this is flexible enough to displace, such as displace between a few micrometres up to tens of micrometers from the ice, where the voids allow for this displacement. For example, the elastic substrate thickness is between 5 micrometers and 4 mm thick, and the substrate displaces between 3 micrometers and 500 micrometers from the ice. A thin elastic substrate may allow using a material with relatively high thermal conductivity, such as 17 Wm/K.

The stage of ice ejection is facilitated by the releases of a seal surrounding the ice. The seal may also assist in ice detachment by keeping the pressure between the ice and substrate high, for example relative to the ambient pressure, so that the ice is completely detached before being ejected. There exist multiple embodiments for the valve's function in separation initiation. There exist multiple embodiments for the substrate's and seal's function in ice detachment. There exist multiple embodiments for the seal's function in ice ejection. Each of these embodiments also includes changes to the valve, substrate, and seal, and thus these three aspects may be implemented differently in multiple embodiments, where the functions may be similar.

Optionally, the edges and/or corners of a grid in an ice cube machine comprise more flexible regions to allow the elastic heat conducting substrate to pass the compressed gas around the corners. For example, each edge of the substrate that defines a corner of between two faces of an ice cube and/or the grid has a region where the substrate is slightly thicker, a local void, and/or the like, to give some additional flexibility over the rest of the elastic substrate. For example, a metal layer covering the flexible material has a hole, a slit, and/or the like. Optionally, ice cube machines have a grid with draft angles in each cube of the grid for easy ejection of an ice block, such as a plate of connected ice cubes.

Optionally, the compressed gas is compressed air. For example, a compressed gas may be air, C0 ₂ gas, and/or the like.

Optionally, the compressed gas is at ambient pressure while the pressure in and around the evaporator grid is below ambient pressure. For example, a suction pump is applied to the evaporator grid and surrounding regions of the ice machine, lowering the pressuring in the voids at least 0.1 bar below the ambient pressure, and the compressed gas entering the valve is ambient pressure gas, such as high-pressure gas. The term high- pressure gas means a gas that is at a pressure above the pressure of the voids in the evaporator grid. For example, when the voids are in fluid connection with a suction pump, the voids may have a pressure 0.1 bar below the ambient pressure and up to 5 bar below the ambient pressure.

Optionally, the grid voids are at least partially interconnected. For example, two or more voids are connected by channels that allow the conversion of pressure at one point between the ice and the grid, such as a first void, to a mechanical force at a second point between the ice and the grid, such as a second void. This interconnection may facilitate the propagation of the compressed gas by further applying mechanical forces to regions where the ice and grid are still firmly attached. For example, the interconnecting channels allow conversion of pressure at a first void to a shear stress of the elastic substrate at another location along the grid.

Optionally, the valve comprises a pin to facilitate the crack initiation or the ice ejection. For example, the pin extends, such as with a mushroom shape, over the gas valve so that ice cannot form on the gas outlet from the valve. For example, the pin is configured to move in the direction of the ice to force the ice to eject from 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), such as 4.35 pounds per square inch above AP, is introduced into the valve, and the flexible walls of the valve expand away from the valve' s center, causing the gas outlet to peel away from the adjacent ice cube filling the grid. This may allow the compressed gas to pass between the ice cube and the grid on a first face of the ice cube, and reach the edges of the first face. When the compressed gas reaches a flexible region along the edges, the compressed gas passes the corner onto the next face of the ice cube. Similarly, the compressed gas passes over the top of the grid to the next ice cube, and thus releases all the ice cubes from the grid. The seal around the grid is now holding the tray of ice cubes to the grid, and by releasing the seal, such as moving a mechanical element, increasing (or decreasing in the case of a negative pressure embodiment) the pressure to an ejection pressure value, such as 0.5 bar above AP, operating a heating element, and/or the like, operating a heating element, and/or the like, the ice cube plate, as in one batch, is ejected from the grid. Optionally, a heating element near the ice seal is heated incrementally until the ice that forms the seal is melted and the ice is ejected. Optionally, both the seal is heated and the pressure is increased (or decreased in the case of a negative pressure embodiment) incrementally until the ice is ejected. Optionally, the hot refrigerator gasses are used to heat the seal.

Optionally, part of the seal or any other part from the ice block is left on the grid, in order tofacilitate ice nucleation on the ejected grid, thereby reducing the water supercooling temperature and energy losses, in the beginning of the next freezing process.

The compressed gas passes between the ice and the grid in part because of the pressure difference between the gas in the voids and the gas in the valve. Once this pressure difference is above a value, such as 0.3 bar, the crack will initiate and propagate until the ice is detached from the grid. This can be done by injecting compressed gas into the valve, or by decompressing the gas in the voids and surrounding the valve. For example, the compressed gas is at a pressure of 0.35 bar above (or below in the case of a negative pressure embodiment) the ambient pressure. For example, the gas pressure in the voids and surrounding the valve is 0.3 bar below AP, such as negative pressure.

Optionally, the seal is heated to melt the ice forming the seal and thus eject the ice cube plate.

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

In wet ice ejection, the grid is heated until the ice plate or tube falls out of the grid, optionally chopped, and into a dispenser. This heating is both time consuming, and requires energy to force heat back into the grid for ejecting the ice. By dry ejecting the ice, both the time for ejection can be shortened relative to wet ejection, and the energy for heating the grid can be saved. Thus, the benefits dry ejecting in ice machines are substantial. The aspects described herein have the benefit of no moving parts in separating between the ice and the grid, and thus are robust and easy to maintain. The aspects described herein are capable of separating ice cubes two or more faces of the ice cube (such as up to all 5 faces of a brick shaped ice cube). Additional configurations of ice cube shapes may benefit from the aspects described herein, such as a variety of faces of ice "cubes" with different cross-sectional shapes, such as star shaped ice cubes, heart shaped ice cubes, as produced in Hoshizaki ice machines, and the like. For example, the elastic substrate and valve may be connected to any evaporator grid, and may be incorporated into existing ice machines with only a few simple changes to the machines. Since the volume of air that is needed to separate the ice is small, such as up to 100 centiliters, the air pump that needs to be added to existing machines is small, and can be pre-pressurized before the ejection.

Following is a table of operational benefits to ice machines (such as an Ice-o- Matic® model ICE0605FA-5 ice machine) using dry ejection according to aspects described herein, with units of kilowatt (KW) and KW-hour (KWh):

Air pump power 0.00 0.0017 KW 0%

Energy per cycle 0.29 0.21 KWh -26%

0.12 0.09 KWh/Kg -26%

5.40 4.02 KWh/lOOlb -26%

TABLE 1

Following is a table of operational benefits to residential refrigerator ice maker, with ice mold with 8 ice cubes mold, 17.5cc each (such as Whirlpool Kenmore Ice Machine Ice Maker Mold and Heater W10190929):

TABLE 2

Following are example illustrations of aspects of certain embodiments.

Reference is now made to FIG. 1, which shows a schematic illustration of an ice machine 100 with dry harvesting. Ice machine 100 comprises a water source 105 configured to flow water over an evaporator grid 101, such as an ice cube grid, an ice plate grid, an ice tube grid, and/or the like. The term grid means the heat conducting surface, such as an evaporator back board, over 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 collector 106 collects water that did not freeze on grid 101 and the water is returned to source 105. Source 105 is also connected to an external water supply. A refrigerator 107 is thermally connected to the grid and removes heat from the water to form ice. Once the ice plate, tube or the like is formed, a gas compressor 109 supplies compressed gas to a gas valve 104, which initiates a separation of the ice from an elastic substrate 103 of the grid. As used herein, the term batch means a quantity of ice formed on the grid, such as a plate, a tube, a series of connected ice cubes, and/or the like. Once the ice batch is separated from the substrate, a seal 102 is activated to release the ice batch from grid 101, and the ice batch drops into an ice dispenser 108. The control operation of water source 105, refrigerator 107, seal 102, and gas compressor 109 is performed by one or more electronic controllers 110 based on sensors connected to grid 101 and water collector 106. Optionally, electronic controller 110 is a computerized controller. Optionally, water for filling water collector 106 flows at least in part along a side of the evaporator during dry harvesting, thereby cooling the new water and further improving the ice machine efficiency.

For example, the at least one controller is an embedded controller, a computerized device, a computer, a server, and/or the like. A controller is configured by firmware, hardware, software, and the like, to control, command, monitor, perform, and/or the like. Software, such as program code, may be configured in modules and stored on a non- transitory storage medium accessible by 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 carry out aspects of the present invention.

The computer readable storage medium can 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 storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage 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 disk (DVD), a memory stick, a floppy disk, a mechanically encoded device such as punch-cards or raised structures in a groove having instructions recorded thereon, and any suitable combination of the foregoing. A computer readable storage medium, as used herein, is not to be construed as being transitory signals per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiber-optic cable), or electrical signals transmitted through a wire. Rather, the computer readable storage medium is non-transient (also "non-volatile").

Computer readable program instructions described herein can be downloaded to respective computing/processing devices from a computer readable storage medium or to an external computer or external storage device via a network, for example, the Internet, a local area network, a wide area network and/or a wireless network. The network may comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and/or edge servers. A 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 instructions, machine dependent instructions, microcode, firmware instructions, state-setting data, or either source code 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 procedural 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, electronic circuitry including, for example, programmable logic circuitry, field-programmable gate arrays (FPGA), or programmable logic arrays (PLA) may execute the computer readable program instructions by utilizing state information of the computer readable program instructions to personalize the electronic circuitry, 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 instructions, which execute via 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, a programmable data processing apparatus, and/or other devices to function in a particular manner, such that the computer readable storage medium having instructions stored therein comprises 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 device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions/acts specified in the flowchart and/or block diagram block or blocks.

Reference is not made to FIG. 2, which shows a flowchart 200 of a method for dry harvesting of ice. When a batch is started, the water loop is started 201 and the refrigerator is started 202. When the ice is ready 203, the water loop is stopped 204A and the gas is compressed 204. The compressed gas initiates 205 a separation of the ice from the substrate surrounding the valve, and the separation is propagated 206 throughout the evaporator grid by the compressed gas and elastic substrate. Ohmmeter sensor may be connected between the elastic substrate 103 and the seal 102, in order to measure the electric resistance during separation propagation 206, for example, when the gas 109 is insulated from the ice. When the ice hasn't separated 207 the gas pressure and grid temperature are incrementally increased 208 until the ice is separated from the substrate. When the ice is separated, the ice batch is ejected 209 such as by operation of a seal, increasing (or decreasing in the case of a negative pressure embodiment) a gas pressure, operating a seal heater, and/or the like. Optionally, a gas pressure is reduced to eject the ice batch.

Reference is not made to FIG. 3, which shows a schematic illustration of an evaporator grid 300 for dry harvesting of ice. Grid 300 has an array of ice cube forming recesses 301 and a groove 302 for forming a seal.

Reference is not made to FIG. 4, which shows a cross section diagram of an evaporator grid 401 for dry harvesting of ice. Grid 401 comprises a refrigerator heat exchanger 402 for drawing away heat from the water to form the ice cubes in grid 401 , such as by using an evaporator back board. When ice is fully formed, gas valve 404 initiates the separation of the ice from grid 401, and passes compressed gas between the ice and substrate 405. Once ice is separated from substrate 405, a seal 406A or 406B is broken to eject the ice from the grid.

Reference is not made to FIG. 5, which shows cross section diagrams of a compressed gas valve 500 for dry harvesting of ice. Compressed gas enters the valve at an orifice 501, surrounded by a valve cushion 502 mechanically connected to an outlet notch 505. In some embodiments, a pin 504 covers an outlet from the valve to prevent water from entering valve 500. A valve cushion pressure release outlet 503 allows the cushion to expand, thereby initiating the separation of ice 507 from the substrate 506.

Reference is not made to FIG. 6, which shows a cross section diagram of measurements of a compressed gas valve for dry harvesting of ice. Cushion outlet diameter is denoted a and cushion wall thickness is denoted c. A pin diameter is denoted b and a pin length is denoted z. Substrate may include a first layer with thickness denoted x and a second layer with thickness donated y. Length of inner valve part may be denoted q and length of expanding cushion portion may be denoted r. For example, ranges of values for dimensions of the gas valve in millimeters (mm) are given in the following table:

c 0.2 5

Q 5 100

R 3 90

X 0.05 2

Y 0.1 4

z 2 40

TABLE 3

Reference is not made to FIG. 7, which shows cross section diagrams of compressed gas valves 700 and 702 for dry harvesting of ice during a separation stage. Valve 700 shows a cushion 701 expanding to initiation a separation between the ice and substrate. Valve 702 shows a cushion expanding without a pin to open a notch 703 in gas valve 702. For example, the notch opens when the cushion 708 expands. This allows compressed gas to pass 706 between the ice and substrate 704 and 705, after first existing the valve through the notch, such as between 707 the valve and the ice.

Reference is not made to FIG. 8, which shows cross section diagrams of a gas bubble 801 generated from a valve for dry harvesting of ice. In this embodiment, the gas in valve 804 is slowly leaked through the notch during the formation of the ice, and after ice is formed gas bubble 801 covers the outlet. The gas bubble reaches elastic substrate 802 and 805 and grid 803, so that when compressed gas is applied to the valve, the separation is initiated by pressure P on elastic substrate 802 and 805.

Reference is not made to FIG. 9, which shows cross section diagrams of a gas bubble 904 generated from a second valve 901 for dry harvesting of ice. Multiple capillaries in valve 901 may allow leaking gas into the water during ice formation, resulting in gas bubble 904. When ice separation is initiated, the passing of the compressed gas between ice and substrate 903 moves substrate against grid 902, resulting in the initiation of separation, as in forming a crack 905. Optionally, the gas bubble over the valve is created by heating the ice surrounding the valve with a heating element 907 inserted into the valve and configured to drain the melted ice water. After the forming of a gas bubble, the ice water drain hole may be blocked with a plug 908. Reference is not made to FIG. 10, which shows cross section diagrams of grid voids 1004 for dry harvesting of ice. Grid voids 1004 in a grid 1001 facilitate the separation of substrate 1002 from ice 1003 by providing a space for the elastic substrate to be displaced by the passing of compressed gas 1005.

Reference is not made to FIG. 11, which shows cross section diagrams of flexible regions 1101 and 1102 of an elastic substrate 1103 for dry harvesting of ice. Since the elastic substrate is compressible only in the direction of the grid, the corners of the elastic substrate, decrease the deflection degree and act as a profile and prevent motion of the substrate in all three directions. Thus, the corners of the substrate may become rigid. To allow the separation of the substrate from the ice to continue around corners, the substrate may include regions where the elastic substrate is more flexible, such as 1101 and 1102. For example, a first flexible region 1101 may include an elongated void around the corner between the substrate and the grid. For example, a second flexible region 1102 may include an increased thickness of elastic material around the corner.

Reference is not made to FIG. 12, which shows cross section diagrams of an ice plate seal 1206 for dry harvesting of ice. Seal 1206 is created by a canted region extending around the ice plate 1205 where the elastic substrate 1202 and 1203 does not extend. This region prevents the compressed gas 1204 from escaping from between substrate 1202 and 1203 and ice 1205, and thus retains ice plate 1205 within grid 1201.

Reference is not made to FIG. 13, which shows a cross section diagram of a separated ice plate seal 1306 for dry harvesting of ice. When the pressure is increased (or below in the case of a negative pressure embodiment), the seal is heated, the seal is mechanically moved, and/or the like, ice plate 1305 will leave grid 1301.

Reference is not made to FIG. 14, which shows a cross section diagram of a mechanically separated ice plate seal 1403 for dry harvesting of ice. When ice plate 1402 is separated from grid 1401, a mechanical level 1404 may move ice plate 1402 away from grid 1401 by pushing seal 1403 away from grid 1401. This mechanism provides a further benefit of building a new ice plate while ice plate 1402 is being transferred to a dispenser.

Reference is not made to FIG. 15, which shows a cross section diagram of a pressure activated ice plate seal 1504 for dry harvesting of ice. When an ice plate 1502 is separated from grid 1501, pressure activated ice plate seal 1504 inside a seal rigid housing 1503 may be activated by receiving compressed gas that causes ice plate seal 1504 to expand or contract, and mechanically break the seal holding ice plate 1502 in grid 1501, and releasing the ice to the dispenser. Reference is not made to FIG. 16, which shows a cross section diagram of a valve 1601 with an ejection pin 1603 for dry harvesting of ice. Cushion 1602 is activated by gas pressure in valve 1601 separating ice plate 1604 from the grid. After separation, the ice plate is ejected by ejection pin 1603 mechanically pushing plate 1604 out of grid.

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

Optionally, a tube ice machine uses dry ejection embodiments as described herein.

Reference is not made to FIG. 17, which shows cross section diagrams of a tube ice machine 1701 with dry harvesting of ice. Tube ice machine 1701 includes two or more tubes 1702 within a case for distributing the refrigerant. Each tube acts as a grid for the forming of tube ice 1703 and includes an elastic substrate 1705 for separating the tube ice 1703. Tube ice 1703 is ejected and a chopper 1704 cuts the elongated ice pieces into shorter ice tubes.

Reference is not made to FIG. 18, which shows lateral cross section diagrams of a tube ice machine with dry harvesting of ice. Each evaporator grid, such as an ice tube 1801, has an inner covering of an elastic substrate 1802, and two or more ejection seals 1803, where the tube base material may act as an evaporator back board.

Reference is not made to FIG. 19, which shows lateral cross section diagrams of an ice tube separation from an evaporator grid 1901 during dry harvesting of ice. The compressed gas from the valve passes between the ice 1905 and the elastic substrate layers 1902 and 1903, causing a separation 1904.

Reference is not made to FIG. 20, which shows a lateral cross section diagram of an ice tube ejection from an evaporator grid during dry harvesting of ice. Once the ice is mostly separated, the two or more seals 2002 separate to form a gap 2001, thereby releasing the ice which falls by the force of gravity towards the chopper.

Reference is not made to FIG. 21, which shows cross section diagrams of alternative ice tube ejection during dry harvesting of ice. A first tube type 2101 may have a star-shaped cross section that is inverted to a flower shape to eject the ice. A second tube type 2102 may have a moveable overlay section 2103 that allows increasing the circumference of tube 2102 to eject the ice. These shapes may be used in residential refrigerator ice makers, that produced half a discus shape ice cubes, with round edge. Optionally, the dry ejection is incorporated into an ice making device as part of a commercial or residential refrigerator, like Whirlpool EZ Connect Icemaker Kit for Top Freezer Refrigerators, model #ECKMFEZ2. For example, each cell in a small grid comprises an elastic substrate and a valve for inserting compressed air between the formed ice and the elastic substrate. Residential refrigerator ice maker may include a metal ice mold with a heater placed on the bottom of the ice mold to melt the ice and release it during wet harvesting. Rotating ejector blades may be used to eject the ice from the ice mold by rotation movement of the blades. At the beginning of the process, water may be poured into one ice cell and flow to all other by small water tunnels and/or channels, such as a small opening in the ice cell side wall. When the water freezes, the 6 to 9 ice cubes connected with small ice bridge formed. During the wet harvesting stage, the small ice bridges melt and the ice cubes separate, producing an esthetic ice cube. In the dry harvesting process, the ice bridges stay as is. To reduce the effect 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 use the blades inside each cell to decrease the water poured into each cell,

(ii) during the water pouring use an inserted volume, such as a cover, so water will spread into adjacent ice cells,

(iii) remove extra volumes in ice cell so water over bridge is displaced into cells, and/or

(iv) the like.

Optionally, the elastic substrate is connected to a suction pump, and during the separation stage the suction pump pulls the elastic substrate from the formed ice.

Optionally, an ice slab of thickness less than 22 millimeters is produced and ejected using a dry ejection embodiment. For example, an ice slab is created in an ice machine with a thickness between 5 millimeters and 25 millimeters, and dry ejection is used to eject the ice slab from the elastic substrate. For example, ice cubes made from an ice slab with thickness less than 20 millimeters have a higher surface area than a typical ice cube, and therefore cool a liquid more efficiently than the typical ice cube. Furthermore, a creating thinner ice slab may be more efficient, such as with a higher evaporator temperature, to manufacture and the ice slab thickness can be preserved better with dry ejection embodiments rather than wet ejection. For example, a 10-millimeter- thick ice slab may use an evaporator temperature of minus 10 degrees Celsius, while an ice slab of 20 millimeters thickness may use an evaporator temperature of minus 20 degrees Celsius.

Optionally, the elastic substrate may comprise a combination of polymers, such as derivatives of polysiloxanes (dimethyle siloxane, H methyl siloaxne and etc.), derivatives of epoxy-based photoresists (SU-8 and etc.), derivatives of polyethylene (PE, PET and etc.) , derivatives of polycarbonate (PC), derivatives of polyamide (PA6), cellulose-containing material (for example Cellulose Acetate), rubber, and/or the like.

Optionally, the elastic substrate may comprise inorganic materials, such as metal oxides (titanium dioxide, zinc oxides, etc.), dielectric materials (silicon dioxide, aluminum oxide, etc.), metals (aluminum, copper, zinc, stainless steel, etc.), and/or the like. Special regions of increased or decreased flexibility may be configured around corners, allowing the compressed gas to pass to most locations between the ice and the grid. The metal cover of the elastic substrate may be shaped in a 'spring shapes', with round edges to achieve more flexibility. Optionally, the edges are less flexible so that a seal is formed within the flexible regions. For example, a rigid area of the elastic substrate may allow forming a seal around the edges of the ice plate during dry ejection.

Optionally, the elastic substrate may comprise high conductivity polymers, such as derivatives of polythiophene (poly(3,4-ethylenedioxythiophene) i.e. PEDOT, polymethylthiophene i.e. PMT, etc.), derivatives of polyphenylene (poly(p-phenylene sulfide) i.e. PPS, poly(p-phenylene vinylene) i.e. PPV, etc.), and/or the like.

Optionally, the elastic substrate may comprise heat conductive additives, such as heat conductive nano/micro particles of carbon, gold, etc., heat conductive nano wires or tubes made from carbon, gold, silver, etc., and/or the like. Optionally, node welding techniques are used to increase conduction, such as a heat conductive micromesh, a millimetric net made from aluminum/steel/copper, and/or the like.

Optionally, the elastic substrate may comprise hydrophobic materials and can be made from manganese oxide polystyrene, zinc oxide polystyrene, precipitated calcium carbonate, carbon nano-tube, silica, derivatives of fluorinated materials, and/or the like.

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

For example, the elastic substrate is comprised of materials that will deform under 0.3 bar of pressure by 10 micrometers. With a thickness of 100 micrometers, the strain will be 0.1 and the elastic modulus will be 300 kilo-pascal. These are rough empirical estimates, and are brought to understand the overall behavior of the elastic substrate. The elastic substrate may have a non-linear elastic behavior due to the flow of the incompressible material into the air voids in the grid changing the thickness of the elastic substrate between the ice and the grid.

For example, an elastic substrate includes a flexible layer of room temperature vulcanization (RTV) silicone (0.2 mm thickness, Shore hardness 40A) and a stiff layer of phosphor bronze (0.1 mm thickness). A valve hole with a flexible part and a 1.5 mm compressed air outlet orifice was able to separate the ice at a pressure of 1/5 bar above ambient pressure and at a temperature of -15 degrees Celsius. For example, without the flexible part of the valve, even a gas pressure of greater than 7 bar above ambient pressure was not able to separate the ice block from an example elastic substrate.

For example, with an elastic substrate of 0.25 mm thickness, a thermal conductivity of 11 Wm/K, and a Shore hardness of 60 (OO scale), an ice cube will be only 3% smaller in volume with the same amount of freezing time.

Optionally, an embodiment includes an ice support plate for using dry harvesting techniques in ice machines. For example, the ice support plate prevents bending stresses in the ice block/slab/plate and a resulting crack in the ice that prevents the propagation of the separation between the elastic substrate and the ice. For example, the ice support plate is a rigid structure with contact points on the ice block, and when the ice freezes it is connected to the ice support plate. This may add mechanical strength to the ice plate during the separation stage of the ice from the elastic substrate.

Reference is now made to FIG. 22, which shows a schematic illustration of an embodiment 2200 for dry ejection with a splash curtain. A water curtain or a water splash curtain 2201, which is located at the front of an evaporator 2202, prevents water from splashing from the evaporator, during the freezing process. At the end of the freezing process water curtain 2201 is pushed by an ice slab 2203. After dry ejection, ice slab 2203 falls to a storage bin.

Reference is now made to FIG. 23, which shows schematic illustration of an embodiment for dry ejection with a splash curtain before ice formation. An ice supporting plate 2301, optionally, attached to a splash curtain, replacing a splash curtain, separate from a splash curtain, and/or the like, may be used for dry harvesting ice machines. Ice supporting plate 2301 may comprise ribs 2302 that may be follow a geometric shape and/or orientation, such as horizontal, vertical, angled ribs, dots, and/or the like. Water 2303 flows between an evaporator 2304 and ice supporting plate 2301 during the formation of an ice plate and starts to freeze on evaporator 2304. Water that doesn't freeze 2303B, flows down to the water reservoir 2305. The ice supporting plate

2301 may serve as a splash curtain.

Reference is now made to FIG. 24, which shows a schematic illustration of an embodiment for dry ejection with a splash curtain after ice formation. At the end of the freezing process, an ice slab 2401 may form on evaporator 2304 and may bond to ice supporting plate ribs 2302. Ice slab 2401 may comprise ice bridges 2402, such as for separation of ice slab 2401 to ice cubes.

Reference is now made to FIG. 25, which shows a schematic illustration of an embodiment for dry ejection with a splash curtain during ice ejection. After the freezing process is completed, compressed air 2501 may be forced between evaporator 2304 and ice slab 2401, and separation begins (i.e. as part of the dry harvesting process). Ice supporting plate 2301 strengthens the ice bridges 2402, and keeps them from breaking during the dry ejection by giving mechanical support for ice bridges 2402 using ribs

2302 connected to support plate 2301. Optionally, water may be forced between support plate 2301 and ice slab 2401 to separate these two, optionally in addition to compressed air 2501, and excess water 2303B may flow into water collection reservoir 2305. For example, the water heats supporting plate 2301 and causes ribs 2302 to separate from for ice slab 2401.

Ice slab 2401 with the ice supporting plate 2301, which may be bonded together, may be pushed away from the evaporator 2304 (i.e. ejection process). Water may flow again between evaporator 2304 and ice slab 2401 or/and between the ice slab 2401 and the support plate 2301, that may be bonded to ice supporting plate 2301, heating and releasing ice slab 2401 from ice supporting plate 2301 and simultaneously, may freeze on evaporator 2304. The pushing mechanism of the ice slab may be electrical or based on a pneumatic actuator mechanism that may push or rotate ice slab 2401 and ice supporting plate 2301.

Reference is now made to FIG. 26, which shows a schematic illustration of an embodiment for dry ejection with a splash curtain after ice ejection. Ice slab 2401 may be released from ice supporting plate 2301 and fall to a storage bin.

Ice supporting 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 assist the air progression in the separation process of the dry harvesting.

Optionally, the ice supporting plate may comprise regions of higher flexibility than other regions, thereby allowing creation of an ice slab without ice bridges by pressing the ice supporting plate to the elastic substrate.

Optionally, the ice supporting plate may comprise air channels for applying compressed air to the grid for ice slab separation, bending prevention during ejection, and/or the like. Optionally, the air channels apply suction to the ice slab and/or elastic substrate.

Optionally, the grid and/or elastic substrate is produced from strips and welded together, such as to produce high drafting angles.

Optionally, the strips comprise a notch to assist in assembly of the grid.

Optionally, the grid has shallow ice cube forming walls. For example, the walls of a grid for dry ice ejection are 10 millimeters in height. For example, the walls of a grid for dry ice ejection are between 3 and 20 millimeters in height. For example, the elastic substrate wall height is 4 mm, and the wall is attached to a flat evaporator board, such as an evaporator back board, without strips, to improve ice machine cost reduction. Throughout this application, various embodiments of this invention may be presented in a range format. It should 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 subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 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 meant to include any cited numeral (fractional or integral) within the indicated range. The phrases "ranging/ranges between" a first indicate number and a second indicate number and "ranging/ranges from" a first indicate number "to" a second indicate number are used herein interchangeably and are meant to include the first and second indicated numbers and all the fractional and integral numerals therebetween.

In the description and claims of the application, each of the words "comprise" "include" and "have", and forms thereof, are not necessarily limited to members in a list with which the words may be associated. In addition, where there are inconsistencies between this application and any document incorporated by reference, it is hereby intended that the present application controls.

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 carry out combinations of special purpose hardware and computer instructions.

The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. 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 terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.