Abstract:
An improved undercounter ice dispenser is disclosed that has a multiple piece auger made in sections for moving ice from the dispenser bin to its ice chute. The auger ice chute invention includes a sensor to reduce ice jamming and to detect when the ice chute is filled or needs filling and works in conjunction with a paddle on the auger to help make the transition. Proportional size ice quantities may also be selected via an interface and auger control.

Description:
DISCLOSURE 
     This application is a United States Non-Provisional patent application, claiming the benefit and filing date of Aug. 25, 2009 of U.S. Provisional Patent Application Ser. No. 61/275,083, and relates to an improved commercial, undercounter ice dispenser and methods for making and servicing the same, and particularly to an ice delivery auger for bringing the ice from an undercounter bin to a counter level dispenser and dispensing the same. 
    
    
     BACKGROUND OF THE INVENTION 
     Heretofore, it was known to dispense ice from an ice bin located underneath a service counter. The advantage of such configuration was the ice dispenser was located at the counter level, but the ice bin and related equipment could be located below the counter and out of sight, thus providing additional counter space. As is well known, counter space is a valuable commodity in a retail establishment, and any increase in counter space is of value. Such undercounter construction is known in the art. One way of bringing ice from the undercounter bin to the counter level dispenser was with an ice auger. Generally, this prior art auger was a one piece assembly (made unitary, such as machined from one piece of aluminum, or originally formed from several pieces and made unitary as by welding) which was from 3 to 5 feet in length, 4 feet being typical. The unitary auger construction was desired because of the loads imposed by the ice on the auger, and the length was necessary to reach from the bottom of the bin to the upper discharge point. 
     The one piece long auger, however, had its own handicaps. The long auger had to be handled carefully as its long length made it more susceptible to being damaged or bent. It was more difficult to install, particularly in the field at the retail outlet. If the dispenser was in a low (9 feet or less) ceiling area, the ceiling could interfere with the removal and installation of the long single piece agitator for servicing, and it might be necessary to move the entire dispenser to a higher ceiling area where it could be serviced. Inventory storage of replacement augers and their shipment to field locations were more difficult due to the auger&#39;s long length. 
     SUMMARY OF THE INVENTION 
     In the present invention a commercial, undercounter ice bin and counter level ice dispenser chute or point have been provided with a multi piece auger, of at least two pieces, so that the auger is assembled from the at least two shorter pieces (say from two 1½ feet to two 2¼ feet sections) into its full auger length (3 to 5 feet). Now the auger could if desired be made in three or even four lengths segments or pieces. The construction of the present invention and method of using the some overcomes the disadvantages of the prior art one piece full length auger. The auger of the present invention being easier to make, install, and service, particularly in the field, store in inventory and ship, is due to its shorter length segments, each of which is also less susceptible to damage and/or bending. 
     Additionally, the undercounter ice bin dispenser of the present invention has been fitted with a proportional ice dispense means and function for dispensing various quantities of ice for various size drinks or cups, improved speed of service, volume, quality and ease of operator use. This means is similar to that disclosed in IMI Cornelius Inc.&#39;s U.S. Pat. No. 6,039,220, which is hereby incorporated by reference. Further, the ice is transported into a visual storage dispense tube so the customer/operator can see the excellent quality ice to be dispensed into the next drink, or if there is a problem, or insufficient amount of ice. The dispenser is also fitted with an ice level sensor at the top of the auger in the visual storage tube, which sensor could be mechanical-electrical, such as a flipper and micro switch, or non-contact, (such as laser, ultra sonic, radar, weight sensors). The sensing device or devices could also be utilized to provide multiple proportion size ice for various size drinks and/or as an input into the control unit for the dispenser. 
     The control unit operates the dispense only when ice is present and the proportional ice delivery system through a customer/operator interface for selecting different size portions of beverages (e.g. large, medium or small). The control system and interface provide feedback means to the customers/operators to alert them as to the dispenser&#39;s performance and prevent a drink dispense unless the proper volume of ice is available for that dispense. 
     The two or more piece auger at its discharge point and end is provided with a discharge paddle to help reorient the ice movement from upward vertically off of the auger to horizontally, to move it toward the top of the adjacent ice discharge chute and prevents heretofore occurring packing and/or jamming at such point, and also assists in moving ice through such change of direction when filling the ice discharge chute. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of the undercounter ice bin, auger, and counter level discharge chute device of the present invention. 
         FIG. 2  is a generally cross-section taken on the lines  2 - 2  of  FIG. 1 . 
         FIG. 3  is a view similar to  FIG. 2 , but showing only the auger tube, auger and discharge chute portions of the present invention. 
         FIG. 4  is an enlargement of the upper portion shown in  FIG. 3 . 
         FIG. 5  is a further enlarged top view of the portions shown in  FIG. 3 . 
         FIG. 6  is a further enlarged cross-sectional view of one form of the ice level sensing means that can be used at the top of the auger tube. 
         FIG. 7  is an elevational view of the discharge chute. 
         FIG. 8  is a perspective exploded view of the auger, its tube and top, and transition cap that feeds ice to the adjacent discharge chute. 
         FIG. 9  is a perspective view of the assembled auger portion. 
         FIG. 10  is an enlarged perspective view of the threaded male portion of the auger that joins to the threaded female portion shown in  FIG. 9 . 
         FIG. 11  is an enlarged perspective view of the female portion of the auger that joins to the male portion shown in  FIG. 9 . 
         FIG. 12  is an enlarged perspective view of the paddle on the top of the top portion of the auger which helps ice transition from upward vertically to horizontally into the top of the ice discharge chute. 
         FIGS. 13 to 19  show alternative means and methods for holding together, joining and/or connecting adjacent auger segments or sections. 
         FIG. 20  is a view of the customer/operator interface or keypad. 
         FIG. 21  is a schematic of the unit shown in  FIG. 1  and its control means. 
         FIG. 22  is a further schematic of the control means and the devices of the dispenser it controls. 
     
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     Referring to  FIG. 1 , an undercounter ice dispenser  14  is shown and comprises a lower portion  16  providing an ice bin  18  that is below the countertop level indicated by the arrow  20  ( FIG. 20 ). The dispenser  14  also includes an upper portion  22  that rises above the counter level  20  and includes the upper portion  24  of a delivery means  26 , in the form of an auger means  28 . The auger means  28  delivers ice into the top  30  of an ice delivery chute  32 . All of these components will be further described below. The counter  33  also contains a service drain area  34  wherein any spilt ice and ice melt water can be collected. 
     As shown more fully in  FIGS. 1 and 2 , the ice bin  18  is contained within a base or cabinet  36  including four sides  38 ,  40 ,  42  and  44 , a bottom  46  and carries the countertop  33 . The ice bin  18 , itself, has an inner surface  50  made of non-rusting material, such as metal, aluminum, stainless steel or plastic. The exterior of these inner surfaces are covered with insulating material  52 . At the bottom of the bin  18 , an agitator  54  and its motor  55  is provided to drive the ice into a lower discharge tube  56 . The lower discharge chute  56  at its bottom intersects with an auger tube  58 . The bin also has an ice sensor  59 . The ice bin  18  also has a removable top  61  to close its upper end. 
     The bottom of the auger tube  58  is mounted in an auger housing  60 , which is closed off except for an opening  62  for a driven portion  64  of the central auger shaft  66 . The auger shaft  66  at its bottom is fitted with a driven gear  68 , which engages a driving gear  70 , which can be rotated by a motor  72 . 
     The auger tube  58  is generally vertically oriented to move ice from the bottom upward to above the counter level  20 . To accomplish this task, the auger means  28  includes a flight or helical portion  76  wrapping around the auger shaft  66 . At the top and bottom, the auger  28  is mounted to rotate in its tube  58 , and as it does so it moves the ice upwards. 
     Heretofore the auger would have been a single, full length piece of from 3 to 5 feet in length. Utilizing one aspect of the present invention, now the auger means  28  and particularly its shaft  66  and its flight  76  are made in two or more longitudinal sections, preferably one of which is about one half or less than the total length of the auger. That is the shaft  66  and is flight  76  of each section are unitary to carry the ice imposed loads, but the auger has at least a lower section  80  (with its unitary shaft and flight) and an upper section  82  (with its unitary shaft and flight). With this construction, it is much easier to remove or install the entire auger (both sections  80  and  82 ), particularly in the field. In the field in low ceiling areas the top section can be removed first, then the lower section of the auger. The multi piece construction also has the advantage noted above, of less susceptible to damage or bending, easier to make, keep in inventory, and ship to field locations. If the auger is made in two or three similar length sections that would also facilitate cleaning the sections thereof in an industrial, commercial or other dishwasher. 
     As noted in  FIGS. 9-11 , the adjacent upper end of the lower portion  80  and the lower end of the upper portion  82  of the auger means  28 , auger shaft  66  and flight  76  are joined to each other at  66 A,  66 B and  76 A and  76 B. The flight portions  76 A and  76 B smoothly lead into each other. One means of forming this connection between the upper  82  and lower  80  sections, is by providing cooperating fastening means, such as male and female threads  90  and  92 , respectively, on the shaft portions  66 A and  66 B. The thread hand is chosen so that auger rotation moving ice upwards tends to tighten such threaded connection. The fully assembled auger  28  with its two or more sections  80  and  82  is shown in  FIG. 9 , and the auger fitting within its auger tube  58  is shown in  FIG. 8 . 
     In  FIGS. 13-19  alternative means and methods of joining the adjacent auger sections are shown.  FIG. 13  shows a male portion  90 E carrying one or more, and here two “O” rings  91 E fitting into a complimenting female opening  92 E.  FIG. 14  shows a “T” portion  90 F formed in one section with a complimentary “T” slot  92 F formed on the other section. The “T” portion only extends partially, in this version about half way, through their respective shaft.  FIG. 15  shows a male splined shaft  90 G and complimentary female splined opening  92 G on the adjacent section. The two sections could be held together by a pin or key  91 G.  FIG. 16  shows male magnetic portions  90 H and a complimentary female magnetic portion  92 H, with the magnets therein being of opposite adjacent poles to attract each other.  FIG. 17  shows a guide rod  90 I secured as by being threaded or pressed into its auger section, with a complimentary female opening  92 I on the adjacent auger section.  FIG. 18  shows a concept somewhat similar to that in  FIGS. 9 and 10 , except the male and female thread portions  90 J and  92 J are in the form of inserts (in this instance not round but hexagonal) that are pressed into the hollowed ends  91 J of the adjacent auger sections.  FIG. 19  shows an off center male projection  90 K that fits into a complimentary offset slot  92 K. Of course the associated upper and lower connections shown in these  FIGS. 9 to 19  could be reversed. That is, for example, the male and female upper and lower parts reversed. 
     Referring to  FIG. 3 , ice is delivered from the bin  18 , up the auger  28  and then into the top of the discharge chute  32 . The discharge chute  32  can be seen in  FIGS. 1 to 7 . The auger tube  58  itself, the auger housing  60  and the mountings for the upper end  96  and lower end  98  of the auger  28  are generally conventional with the motor gear case providing lower bearing means and holding the auger  28  generally centered in the tube  58  with the tube  58  providing any needed additional centering or other guidance. The tube  58  is made of rust resistant material, such as metal, aluminum, stainless steel or plastic. 
     The auger  28  at its top  96  discharges into a transition cap portion  102  of the discharge chute  32 . The transition cap portion  102  is shown in  FIGS. 1 to 7  and is generally cylindrical having a side wall  104  with a top wall  106  and a downwardly and outwardly inclined discharge outlet portion  108 . This cap  102  is held to the top of the auger tube  58  as by a metal retaining wire  105  that is secured to the unit&#39;s superstructure. The auger tube  58  at its lower end is held in place and aligned with the opening of the lower discharge tube  56 . 
     The present invention includes ice sensor level means  110  (See  FIGS. 2 to 7 ) at the top of the transition cap  102  to keep the auger running at a maximum efficiency, providing a signal for turning the auger “on,” when ice is needed in the discharge chute  32 , and the auger “off,” when ice is not needed. Previously, such ice level sensors were not provided in prior art under counter units. In the present embodiment, the ice sensor  110  includes the mechanical ice level flapper  112  which is pivotally mounted on the cap top  106  ( FIGS. 3 ,  4 ) by a pivot point or rod  114 . The contact portion  116  below the pivot  114  of the flapper  112  can be pivoted into contact with a micro switch  118  to provide a signal to turn on and off the auger  28 . The flapper  112 , itself, is curved to encourage, and not discourage, ice flow, and as full ice is reached raised upward and/or out of the way so as not to inhibit ice flowing from the auger to the ice discharge chute. This signal from the ice level sensor  110  is led to the unit&#39;s  14  control means  120  shown in  FIGS. 21 and 22 . Other means could be used to sense ice levels rather than the shown mechanical/electrical (micro switch) flapper sensor, for example, laser, ultra sonic or radar sensors could be used. With ice level optiminally controlled, it is easier to transfer ice from the auger  28 , through the cap  102  and into the discharge chute  32  without packing or jamming. The ice sensor  59  in the ice bin  18  will also control and shut off the unit if no ice is sensed. 
     Referring to  FIGS. 2 ,  8 ,  9 ,  10  and  12 , the top  96  of the auger  28  upper section  82  is provided with a transfer paddle  130  which as it rotates with the auger, assists in moving the ice off of the auger and horizontally into the cap and discharge chute. The paddle  130  is generally rectangular and no greater, actually slightly less than, the radius of the auger tube  58 . The paddle  130  could be integrally formed with the auger shaft  66  and flight  76 , or welded thereto. The paddle  130  would be made of the same material as or compatible to the auger, its shaft and flight. 
     The paddle  130  delivers the ice to the top of the discharge chute  32 , from which it can be discharged into a container or cup, placed below the lower end of the discharge chute. 
     The discharge chute  32 , like the rest of the chute, is made of clear plastic such as polycarbonate plastic. The discharge chute is otherwise somewhat similar in construction to that used on IMI Cornelius&#39;s non under counter ice dispenser chutes. The clear chute has the advantage of visually confirming that there is ice in the chute for delivery and provides a desirable appearance, indicating cleanliness and quality ice delivery. The bottom of the discharge chute  32  is closed by a gate  131  operated by an air cylinder  133 . 
       FIGS. 21 and 22  show a user/customer interface  190  which is the form of a keypad with eight keys (1 to 8) for: ice for various drink sizes, manual override buttons, and programming button with selectors to scroll up and down. 
     The unit as shown in  FIG. 21  has a control  198  and also utilizes the proportional ice delivery system  120  used in IMI Cornelius&#39;s non undercounter units and generally shown in U.S. Pat. No. 6,039,220, mentioned above. The device  14  draws 120 volt AC current from a source or plug  200  which is provided to a heater  202  to keep the mechanicals of the device or unit from freezing. That line voltage is also supplied to a voltage dropping and isolation transformer  204 , which provides 24 voltage to portions of the unit. The auger motors  72  and agitator  55  work a full line voltage. The line voltage can also be supplied to the double pole contacts of the relay  206  for the agitator motor  55 . The agitator motor  55  powers the agitator  54  within the ice bin  18 . This relay has a coil  210  which is part of the control system and its being energized closes the contacts of relay  206  to operate the motor  55  and its agitator  54 . The unit also has a separate auger motor  72  to drive the auger  28 . The auger motor  72  operates at full line voltage of 120 volts. The 24V DC power supply  224 , via the circuit and voltage dropping resistor, is used to provide 5 V DC supply  238  for the device&#39;s control circuits. The 24 V AC is inputted into power supplies  234  and  238  to provide 24 V DC and 5V DC output currents respectively. The potentiometers  240 ,  242  and  244  input into the control circuits and are used to set and/or adjust “auger speeds”, “on time”, and “off time” to control the running of the auger  28  as desired. Two on-off type sensors or switches  59  and  110  are provided for the ice bin  18  and ice chute  32  to control operation of the device and, particularly, the auger  28  and its motor  72 . If the ice chute sensor  110  or ice sensor or switch  59  indicates empty or the fill door sensor or switch  224  senses an open door position, the auger  28  is prevented from turning or operation. To the extent  FIGS. 21 and 22  have not been described, the system shown is similar to that used in prior art undercounter dispensers. 
     The  FIG. 21  control system is different from the prior art in that an on-off sensor or switch  110  is provided on/in the cap or cover  102  to sense when the auger  28  and ice chute  32  are already filled with ice and prevents operation of the auger  28  in that condition to avoid jams and damage. When that ice is discharged and/or below maximizing, that sensor or switch  110  provides an input to the control system that would permit the auger  28  to turn or operate to refill the ice chute  32  for the next use. The sensor or switch  110  is provided between and in series with the ice chute sensor and sensor  59 . 
     Further as noted, the input interface keyboard  190  is provided for the operator/customer inputting selected and different ice quantities amounts for different size ice drinks. The interface  190  connects to the proportional ice control unit  120 , which also has a display screen  274  for displaying inputs/outputs and trouble codes. The proportional control contains a logic portion or CPU  212 , a power supply  278 , ice bin input circuit  280 , ice door or flap input circuit  282 , a piezoelectric sounder  284 , and a R8-232 port interface, indicated at  288 , for a telephone hookup to provide for remote operation, troubleshooting and alarms. This unit also operates the air gate solenoid  290  which opens and closes the air cylinder  135  and the cup fill door or gate  131 . This proportional ice unit  120  is similar to that described in U.S. Pat. No. 6,039,220, and/or sold by IMI Cornelius on its prior art model ED250 PROGATE above counter ice dispensers. 
       FIG. 22  shows how the controller  120  and its dispenser main PC board  204  and its keypad/customer interface  190 , and PC Board  206  are used to control and operate the air cylinder  135  and its solenoid  290  which operates the air cylinder  135  for the ice chute lower discharge gate  131 . The LED display  274  is, for example, a four or five character display, so that an output, for example, “PRG” (for purge) could be displayed. The ice hopper ice level sensor  59  and ice chute level sensor  110  input to the CPU  212  in the interface PC board  206 . The main PC board  204  also controls the ice hopper agitator motor  55  and the ice auger motor  72 . Power is supplied to boards  204  and  206 , via a source  218 , a line voltage terminal board (to maintain voltage/power quality)  220  and to a 24 volt transformer  222  for use in 24 volt safety switches  224  to prevent injury by the agitator or auger when the covering guards, housings and potential moving parts are exposed or are removed, which operate via a relay  228 , to the master relay  236  which would shut down the entire unit. 
     While the preferred embodiments have been disclosed and described, it should be understood that equivalent elements and steps of those described in the appended, claims would fall within the scope of those claims.