Abstract:
An ice dispensing apparatus is described which is capable of dispensing free ice or ice in a sealed bag. The apparatus has an ice manufacturing zone capable of converting incoming water to ice. An ice storage zone receives the ice from the ice manufacturing zone. An ice distribution zone has a distributor capable of receiving the ice from the ice storage zone and distributing the ice to a free ice chute or an ice bagging station wherein the free ice chute discharges ice to an exterior receptacle. The ice bagging station has a bag funnel capable of receiving ice and passing the ice in a downward flow of predetermined size. A bag storage device stores multiple bags prior to use. A bag grabbing device removes a bag from the bag storage device and bag filling hold the bag with a mouth opened to a size which is at least as large as the predetermined size whereby the ice passing through the bag funnel is collected in the bag. Bag closing pins hold the bag with the mouth in an orientation for sealing. A sealer converts the mouth of the bag to a seal.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention is related to an apparatus for making and dispensing ice. More specifically, the present invention is related to a mobile apparatus capable of providing large volumes of ice for distribution into either user supplied receptacles or bags which are filled and sealed within the apparatus. 
         [0002]    There are many large events which have a demand for high volumes of ice over a short period of time. Typical events include sporting events, political events, disaster locations, mobile medical care situations and the like. The most common way in which such events are supplied is to provide bagged ice in a refrigerated truck or trailer. This is costly and may be difficult to do, particularly, when the event is not accessible in a reasonable amount of time. 
         [0003]    The present invention provides an ice dispensing apparatus which can be transported to a location by air, land or sea and which can act as a stand-alone ice manufacturing and dispensing station with the capability of dispensing in either a chute for collection in receptacles, or in sealed bags. 
       SUMMARY OF THE INVENTION 
       [0004]    It is an object of the invention to provide an ice dispensing apparatus which is mobile, yet, capable of manufacturing and dispensing large volumes of ice. 
         [0005]    It is yet another object of the invention to provide an ice dispensing apparatus which can dispense ice directly from a chute or in sealed bags. 
         [0006]    A particular feature of the present invention is the compact nature of the apparatus. 
         [0007]    These and other advantages, as will be realized, are provided in an ice dispensing apparatus. The apparatus has an ice manufacturing zone capable of converting incoming water to ice. An ice storage zone receives the ice from the ice manufacturing zone. An ice distribution zone has a distributor capable of receiving the ice from the ice storage zone and distributing the ice to a free ice chute or an ice bagging station wherein the free ice chute discharges ice to an exterior receptacle. The ice bagging station has a bag funnel capable of receiving ice and passing the ice in a downward flow of predetermined size. A bag storage device stores multiple bags prior to use. A bag grabbing device removes a bag from the bag storage device and bag filling hold the bag with a mouth opened to a size which is at least as large as the predetermined size whereby the ice passing through the bag funnel is collected in the bag. Bag closing pins hold the bag with the mouth in an orientation for sealing. A sealer converts the mouth of the bag to a seal. 
         [0008]    Yet another embodiment is provided in a method for providing ice. The method includes:
   converting water to ice in an ice manufacturing zone;   transporting the ice from the manufacturing zone to an ice dispensing zone;   moving a director to a position selected from a free ice dispense position and a bagged ice dispense position wherein when the director is in a free ice dispense position the ice passes through the director to a free ice chute;   wherein when the director is in a bagged ice position the ice passes through the director into a bag wherein the bag has an open mouth which is held open by bag filling pins;   and sealing said bag.   
 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0014]      FIG. 1  is a side schematic view of an embodiment of the invention. 
           [0015]      FIG. 1A  is a back side view schematic view of an embodiment of the invention. 
           [0016]      FIG. 2  is a side cross-sectional view of an embodiment of the invention. 
           [0017]      FIG. 2A  is an alternative embodiment of the invention. 
           [0018]      FIG. 3  is a schematic view of the bag filling mechanism. 
           [0019]      FIG. 3A  is a schematic view of the hopper assembly of the bag filling mechanism. 
           [0020]      FIGS. 4-10  illustrate the stepwise operation of the bag filling station. 
           [0021]      FIG. 11  is a flow chart representation of an embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0022]    The present invention is specific to an apparatus for manufacturing and dispensing ice. More specifically, the present invention is related to an apparatus which can dispense ice from a chute, for capture by a receptacle provided by the user, or in sealed bags. 
         [0023]    The invention will be described with reference to the various figures which form an integral, non-limiting, part of the specification. Throughout the specification, similar elements will be numbered accordingly. 
         [0024]    An embodiment of the invention is illustrated in side view in  FIG. 1 . In  FIG. 1 , the ice dispensing apparatus, generally represented at  10 , comprises a shell,  12 , within which the ice making, storage and dispensing occurs. A door,  14 , provides access to the interior of the shell for maintenance and restocking of bags. The shell is preferably insulated to minimize ice melting within the shell. At least one optional light,  16 , is provided on the exterior of the shell for visibility in night time operations. An optional access door,  2 , allows access to a storage area. 
         [0025]    The shell is preferably mounted on a carriage,  18 , which may have optional mobility elements,  20 , such as wheels. The carriage may be integral to the shell or the shell may be removable from the carriage. In one embodiment the shell is transported to a location and then placed on a carriage during use. Transport can be by air, land or water. 
         [0026]    A back side schematic view is illustrated in  FIG. 1A . In  FIG. 1A  the free ice door,  3 , is illustrated wherein free ice exits the apparatus for capture in a receptacle such as a cooler. A bag ice door,  4 , is illustrated wherein bagged ice exits the apparatus. A user interface,  5 , allows the user to request the manner in which ice is to be dispensed, bagged or free, and allows the user to pay for the ice if necessary. 
         [0027]    The apparatus is illustrated in side cross-sectional schematic view in  FIGS. 2 and 2A . The apparatus will be defined with reference to three distinct zones. Zone A is an ice manufacturing zone. Zone B is an ice storage zone and Zone C is an ice dispensing zone. Each zone will be described separately. 
         [0028]    The ice manufacturing zone, referred to herein as Zone A, receives water through a water coupler,  30 . Water is preferably supplied from an exterior source such as a municipal water supply, a well, a lake, a pond, a water transport device or the like. An optional, but preferred, filter,  31 , is provided to remove contaminants. The source of water is not particularly limited herein with the exception that the water must be suitable for the intended use. If the ice is to be used for drinking purposes the incoming water must be potable water as would be realized. The water enters an ice maker,  32 , which freezes the water into ice cubes of a predetermined shape and size. The ice can be manufactured in the desired size or manufactured in a larger size and then reduced such as by crushing. Manufacturing at the intended size of dispensing is preferred. The construction of the ice maker is not particularly limited herein. The most common type of ice makers utilize adiabatic expansion of a refrigeration medium, such as a halogenated hydrocarbon, as the cooling mechanism. A compressor,  34 , compresses the refrigeration medium thereby liberating heat which is expelled into an environment exterior to the refrigeration unit. The refrigeration medium is allowed to expand in an expansion chamber,  36 , such as a coil, within the ice maker thereby absorbing heat. 
         [0029]    The ice is transferred from the ice maker to the ice storage zone, Zone B, for storage until a request for ice is made by a user. In one embodiment, the ice is dispensed from the ice maker to a maker chute,  38 , wherein it enters a storage transfer element,  40 . The storage transfer element may be a conveyor which rotates, as indicated by the arrow,  42 , wherein the ice is allowed to fall into the ice storage zone through a passage,  44 , between the ice manufacturing zone and the ice storage zone. In an alternative embodiment an auger,  41 , transfers the ice as illustrated in  FIG. 2A . 
         [0030]    The ice storage zone is preferable a storage cavity,  46 , which functions as an ice holding tank within which ice is stored. A dispense unit transport element,  48 , transfers the ice from the ice storage zone to a ice dispensing zone. In a preferred embodiment the dispense unit transport element is an auger,  50 , which transports the ice by rotation. A collector,  52 , preferably extending between the interior walls, partially encloses the auger and persuades all ice towards the auger. A sloped collector floor,  54 , also persuades the ice towards the auger. The collector and collector floor work in concert to insure that ice is persuaded towards the auger by gravity. A motor,  56 , turns the auger as would be realized. A secondary cavity,  58 , below the storage cavity is preferably a dry area which may be used for storage and the like. An agitator,  60 , agitates the ice within the cavity to prohibit the formation of pockets and bridging within the ice which are referred to in the art as “rat holes”. An auger is a preferred agitator due to its ability to move ice laterally. Other rotating shafts, such as a shaft with fingers extending there from can be used. A motor,  61 , turns the agitator. When ice is poured into the top of a cavity and withdrawn from the bottom it is not uncommon for the ice to form bridges across structural elements with a void below wherein the ice below the bridge has been removed. The ice in the bridge can be substantial and can prohibit further migration of ice towards the auger. In practice, the operation ceases with the ice machine incorrectly sensing a full ice holding zone and the ice dispensing zone no longer receiving ice. The agitator agitates the ice thereby inhibiting formation of ice bridges within the storage cavity or breaking those that have formed. The agitator preferably operates on a predetermined time frame which is independent of the dispensing operation. The agitator may be continuous or it may operate on a fixed intermittent schedule. In a preferred embodiment the agitator operates on a predetermined schedule with an override for additional agitation on demand when a decrease in ice is determined at the ice dispensing zone since this is suggestive of ice bridge formation. In this instance additional rotation is triggered thereby dislodging any ice bridge. The agitation auger can turn in one direction or in a oscillatory motion. 
         [0031]    The dispensing zone, Zone C, provides two dispensing options. In one option the ice is dispensed in free flow form, by a free chute,  62 , and in another option the ice is dispensed in a sealed bag by a bag chute,  64 . 
         [0032]    The auger,  50 , is preferably enclosed in an auger tube,  68 , within the dispensing zone thereby prohibiting ice from escaping the flow path created by the auger. A hopper,  66 , receives the ice from the auger of the dispense unit transport element. A director,  70 , directs ice to either the free chute or a bagging station. If ice is directed by the distributor to the free chute the ice flows, preferably by gravity, to a free ice door ( 3  of  FIG. 1A ) in the shell for collection in a receptacle. If ice is directed by the distributor to the bagging station it first enters a distributor,  72 , which directs ice into an open end of a bag as will be better understood after further discussion below. Bags,  74 , are stacked on a bag storage device,  76 , preferably by wickets,  78 , which are received by apertures in the individual bags as will be more fully understood after further discussion below. The bag storage device,  76 , has a channel,  80 , which allows the bag storage device to rotate on a pivot,  82 , in concert with the angle of the bag chute,  64 , which is adjusted by a hydraulic cylinder,  83 , as will be more fully described below. A control panel,  84 , which may be exterior to the shell, controls the ice maker, agitation, ice transport and various control aspects of the apparatus. A climate control element,  86 , is preferably in the dispensing zone to control temperature and humidity at an optimum level. 
         [0033]    A partial cut-away view of the bagging station is provided in  FIG. 3 . In  FIG. 3 , the hopper,  66 , receives the ice as described above. The director,  70 , directs ice into a distributor,  72 . The distributor has an angled floor,  87 , with a peak. The floor is sloped away from the peak in each direction. The director drops the ice on either side of the peak depending on the request. On one side of the peak the ice will flow to the free chute,  62 , by gravity feed and on the other side of the peak the ice will flow to a bag funnel,  88 , which directs the ice into a bag. For the purposes of illustration a bag is not in position for receiving ice in  FIG. 3 . A plunger cylinder,  92 , will extend a plunger (not visible) which will grab a side of a bag from the bag storage device and draw to bag to open the mouth of the bag a certain extent. Four filling pins,  90 , enter the mouth of the bag and extend to open the mouth of the bag into a rectangle which is at least as large as the bag funnel. Therefore, ice flowing into and through the bag funnel will drop directly into the bag. When the bag is full, preferably based on a determination of weight by the bag chute,  64 , a pair of bag closure pins,  91 , enters the open mouth of the bag. The filling pins are collapsed and removed from the mouth and the bag closure pins move away from each other thereby greatly increasing the length of the rectangle formed by the open mouth of the bag at the expense of the width. The bag closure pins preferably extend to form a rectangle which is essentially the same width as the thickness of the bag closure pins without significantly stretching the bag. Mating thermal sealers,  95 , approach each other just below the bag closure pins and with the bag there between. The thermal sealers press the bag closed and form a seal, preferably, by heat. The bag is then released and slides down the bag chute due to gravity. In one embodiment the ice is weighed by the bag chute. In another embodiment the ice is weighed by the hopper. In another embodiment the ice is weighed by the filling pins. 
         [0034]      FIG. 3A  is an isolated view of the hopper. The distributor and hopper move, as indicated by the arrow, relative to each other such that the ice from the hopper falls on the angled floor on the appropriate side of the angled floor for the ice to be directed to the appropriate distribution mode. 
         [0035]      FIGS. 4-10  schematically illustrate the preferred bag filling mechanism of the invention in more detail. In  FIG. 4 , the bag funnel,  88 , indicated by dashed lines, is positioned over the eventual location of an open bag. The filling pins,  90 , are in a rectangular configuration with opposing arms in close proximity. A plunger cylinder,  92 , and associated plunger,  93 , are in a position with the plunger retracted. The bags,  74 , are on the bag storage device,  76  and suspended by wickets,  78 . 
         [0036]    In  FIG. 5 , the plunger,  93 , is extended from the plunger cylinder,  92 , to the extent necessary to grab the closest bag preferably by suction. In  FIG. 6 , the plunger,  93 , is retracted drawing the bag there with. The bag is still partially captured by the bag storage device thereby persuading the mouth of the bag to open to the extent necessary for the bag filling pins to fit within the open mouth of the bag. 
         [0037]    In  FIG. 7 , the bag filling pins move away from each other which forms a rectangular mouth on the bag with the rectangle extending beyond the boundary of the projection of the bag funnel,  88 . Therefore, as ice falls from the bag funnel the ice will enter the bag. 
         [0038]    Once the bag is full, as determined by weight or volume, the bag is sealed. With reference to  FIG. 8 , the bag filling pins are withdrawn from the bag in favor of the closure pins,  91 , which are placed in the mouth of the bag. As illustrated in  FIG. 8 , the closure pins are withdrawn from each other thereby drawing the two sides of the bag together wherein the two sides are in close proximity and substantially parallel to each other. 
         [0039]    The bag is now ready for sealing as illustrated in  FIG. 9 . In  FIG. 9 , the mating thermal sealers move counter to one another and press the walls of the bag there between wherein the walls of the bag are in contact. The mating thermal sealers fuse the bag thereby forming a seal. As illustrated in  FIG. 10 , the bag, now with a seal,  96 , is allowed to slide down the bag chute,  64 , wherein it slides out of the apparatus due to gravity. The bag is preferably supported by the bag chute during filling. 
         [0040]    A flow chart illustrating the operation of the apparatus is provided in  FIG. 11 . A controller,  100 , receives a request for ice from an input receiver,  102 , which is preferably accessible on the exterior of the apparatus. The input receiver can be a push button device wherein a user makes selections of how ice is to be dispensed by selecting a button which indicates bag or free. The input receiver may include a payment system such as a coin or bill collector or reader or a card reader. In general, the input receiver allows a user to request that ice be dispensed in either free flow form or in a bag in predetermined amounts or user determined amounts. The controller monitors each zone and controls various functions. 
         [0041]    If a request for ice is made at  102 , the controller relays the type of request to the ice dispensing zone, Zone C at  104 . A determination of bagged ice is made at  106 . If bagged ice is not to be dispensed the controller determines if the director is over the free chute at  108 . If the director is not over the free chute the director is moved at  110  and ice is dispensed at  112  to the free chute. If bagged ice is requested the controller determines if the director is over the funnel at  114 . If the director is not over the funnel the director is moved at  116 . A bag is grabbed from a bag stack at  118 . For the purposes of illustration the bag is grabbed from the stack after with the director in proper location for dumping ice in the bag, however, it would be understood that the timing for placing a bag in ice receiving position may be independent of the director positioning. In one embodiment the bag may be placed in receiving position upon receiving a request for a bag of ice. In another embodiment a bag may be placed in receiving position after distribution of a previous bag thereby having a bag available prior to receiving a request for bagged ice. 
         [0042]    The bag is opened at  120  and ice is added at  122  until the bag is determined to be full at  124 . Once the bag is full the bag is partially closed at  126  and sealed at  128 . The bag is dispensed at  130 . The determination of a full bag may be by weight or by volume dispensed with weight being preferred. 
         [0043]    The controller,  100 , monitors the status of the ice storage zone, Zone B. It is preferable to maintain ice between a minimum level and a maximum level. The minimum level is a level below which there is insufficient ice for the anticipated demand. The maximum level may be a full ice storage zone or the maximum level necessary to insure adequate supply to the dispensing zone. For the purposes of discussion the maximum is referred to as full and the minimum is referred to as empty. A determination is made as to whether the ice holding zone is full at  132 . If the ice holding zone is not full a determination is made as to whether the ice holding zone is below the minimum level at  134 . Once the ice is below the minimum level an indication to add ice is made at  136 . 
         [0044]    When ice is requested from the ice manufacturing zone, Zone A, a determination is made as to whether the ice is frozen at  138 . If the ice is not frozen a timer is set at  140 , for a recheck after a predetermined time. Once the predetermined time is met the determination is made again as to whether the ice is frozen at  138 . Once the ice is frozen it is dispensed to the ice storage zone at  142 . 
         [0045]    The controller is illustrated as a single unit even though one of skill in the art would appreciate that the controller may include separate controllers with manual interaction there between. A controller which integrates all three zones without human intervention is most preferred. In another embodiment certain elements of the controller may be separated. As would be realized the controller preferably has override mechanisms allowing a master user to operate certain elements of the apparatus independently of others for diagnostic and maintenance purposes. 
         [0046]    The invention has been described with reference to the preferred embodiments without limit thereto. One of skill in the art would appreciate additional embodiments, alterations and adaptations which are not specifically recited but which are within the scope of the invention as more specifically set forth in the claims appended hereto.