In version 1.6.3 of i1Profiler, it appears (for the i1Pro2 at least) that they've tweaked the minimum patch size a bit (and maybe the algorithm too) allowing about 15% more patches. I used to be able to get 1215 patches on 2x Letter sheets w/ maximum grey ramp.
Under the new version, I can get 1386 patches. The number of rows went from 18 to 21 but 1 less column.