Patent Abstract:
An ice crusher is attached to an ice dispenser or to a combined ice and beverage dispenser. The ice crusher occupies minimal space in order to fit the dispenser into an existing space on a serving counter or in a beverage dispensing area. The ice crusher may also elevate the ice. In embodiments using this technique, the outlet of the ice from the ice crusher is higher than the ice inlet. As the ice flows from a source of ice, such as an ice bin, the ice is elevated while it is being crushed. The ice then flows from the outlet of the ice crusher down an ice chute or other outlet of the ice crusher, into a cup or container as desired. Other embodiments convey the ice without lifting it, and still other embodiments dispense either crushed or cubed ice, as the consumer may select. In one embodiment the selected crushed ice or cubed ice are both dispensed though the same ice dispensing chute. A retrofit kit may be used to add an ice crusher to an existing ice dispenser, or to an existing combined ice and beverage dispenser.

Full Description:
REFERENCE TO EARLIER FILED APPLICATIONS 
       [0001]    The present application is a divisional application of U.S. patent application Ser. No. 11/514,715, filed Sep. 1, 2006, which claims the benefit under 35 U.S.C.§119(e) of Provisional U.S. Patent Application Ser. No. 60/713,983, filed Sep. 2, 2005; both of which are hereby incorporated by reference in their entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    The technical field of the invention is that of ice dispensers, and ice and beverage dispensers. 
       BACKGROUND 
       [0003]    Commercial ice dispensers, such as those used in fast-service restaurants, are built in a compact design to increase the ice storage area within a given space. Many customers of fast-service restaurants, as well as consumers generally, are accustomed to having ice in their beverage. Of course, this means that there must be an ice dispenser nearby, or the beverage dispenser may include an ice bin and an ice dispenser. In some applications, such as one depicted in U.S. Pat. No. 6,761,036, assigned to the assignee of this invention, the beverage dispenser may even include an ice maker so that users need not manually transport ice, such as cubed ice, into the ice bin for later dispensing by customers or by store personnel. In addition to standard cubed or shaped ice, consumers have come to appreciate shaved or crushed ice in their beverages. The smaller flakes or shavings, with much greater surface area, are able to cool a beverage much more quickly than a standard cube of ice. People also enjoy the feel of crushed ice in their mouths, and are better able to chew crushed ice. 
         [0004]    One problem with dispensing ice is that ice makers, ice bins and ice dispensers require space in very crowded serving and dining areas. Space is sufficiently limited that ice dispensers have been integrated into beverage dispensers to save space, and ice makers, as mentioned above, have been integrated into beverage dispensers in order to avoid placement of an extra machine into dining or serving areas. Of course, if crushed or flaked ice is now desired, that may mean another machine is needed, such as an ice crusher, or adapting an existing ice maker or beverage dispenser to add an ice crusher. The same problem of lack of space acts as a barrier to the addition of an ice maker or an ice crusher. Dispensing previously-crushed ice is difficult, as in U.S. Pat. No. 6,109,476, since the ice tends to form clumps in the ice bin and may not readily be conveyed from the bin. 
         [0005]    In addition, the design of beverage dispensers typically does not allow room for a crusher to be easily placed into an existing dispenser. In particular, if an ice crusher is to be added to a beverage dispenser with an ice bin, especially if an ice maker is also included above the ice bin, there should be sufficient room (height) between the ice bin and the beverage dispenser to fit in the ice crusher. Low ceilings or other obstacles to height may make this additional height objectionable. What is needed is therefore an ice crusher that will dispense ice from an ice bin and will crush ice from the ice bin without adding to the height of an existing machine 
       BRIEF SUMMARY 
       [0006]    An ice dispenser with an integrated ice crusher has been invented which now makes it possible to provide crushed ice at the point of ice delivery to a customer&#39;s cup. The small size and arrangement of the ice crusher allows the ice crusher to be integrated into the dispenser without significantly increasing either the height or footprint of the dispenser. The integrated ice crusher can also be used on a combined ice and beverage dispenser. Preferred ice and beverage dispensers allow for the delivery of either crushed or cubed ice according to the consumer&#39;s choice. 
         [0007]    In a first aspect, the invention is a combination of an ice dispenser with an ice crusher. The combination includes a non-refrigerated ice bin; an ice crusher housing having an inlet connected to the ice bin; an ice crusher within the ice crusher housing; and an outlet for crushed ice from the ice crusher housing. In one embodiment the ice crusher includes at least one rotating and at least one non-rotating crusher blade within the ice crusher housing. 
         [0008]    In a second aspect, the invention is a combination of a beverage dispenser and an ice crusher. The combination includes a beverage dispenser having an ice bin with a cold plate, wherein syrup for at least one beverage is routed through tubing in the cold plate. The combination also includes an ice crusher housing having an inlet connected to the ice bin; an ice crusher within the ice crusher housing; and a crushed ice outlet from the ice crusher housing. 
         [0009]    Another aspect of the invention is a method for crushing and dispensing ice from an ice dispenser. The method comprises transferring ice from a non-refrigerated ice bin to an ice crusher housing containing an ice crusher; crushing ice in the ice crusher; and conveying crushed ice through an outlet from the housing of the ice crusher. 
         [0010]    In another aspect, the invention is a method of operating a beverage dispenser with an integrated ice dispenser, the beverage dispenser having at least one mixing and dispensing valve for mixing a syrup and water and dispensing a beverage. The method includes a) selecting whether crushed ice or cubed ice is to be dispensed and activating ice dispensing; b) in response to a selection of crushed ice in step a), i) causing ice cubes to be delivered to an ice crusher housing; ii) crushing the ice cubes in the ice crusher housing, and iii) delivering the resulting crushed ice to an ice dispensing chute; and c) in response to a selection of cubed ice in step a), delivering cubed ice to the ice despising chute. 
         [0011]    In still another aspect, the invention is a method of operating a combined ice and beverage dispenser, wherein the beverage dispenser comprises at least one mixing and dispensing valve for mixing a syrup and water and dispensing a beverage, and wherein the ice dispenser is equipped with an ice crusher. The method includes a) selecting whether crushed ice or cubed ice is to be dispensed and, when crushed ice is selected, b) causing cubed ice to pass into the ice crusher, and c) activating the ice crusher, thereby crushing the ice. 
         [0012]    A further aspect of the invention is a combined ice and beverage dispenser having at least one mixing and dispensing valve for mixing a syrup and water and dispensing a beverage, an ice bin, first and second openings out of the ice bin, an ice crusher and a selector for selecting whether the dispenser will deliver cubed ice or crushed ice. 
         [0013]    A still further aspect of the invention is a combined ice and beverage dispenser having at least one mixing and dispensing valve for mixing a syrup and water and dispensing a beverage, an ice bin, first and second openings out of the ice bin, an ice crusher and two dispensing chutes, one for cubed ice and one for crushed ice. 
         [0014]    Another aspect of the invention is a retrofit kit for adding an ice crusher to an existing ice dispenser. The retrofit kit includes an ice crusher in an ice crusher housing attachable to the existing ice dispenser and an ice dispensing chute attachable to the ice crusher housing. 
         [0015]    There are many other aspects and embodiments of the invention, only a few of which are described in the attached drawings and in the presently preferred embodiments below. With the preferred embodiments, restaurateurs are able to provide crushed ice with virtually no increase in the equipment footprint. Users are able to enjoy crushed ice with the same degree of timeliness and convenience that they are accustomed to for cubed ice. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIG. 1  is an exploded view of an embodiment of an ice dispenser with an integral ice crusher. 
           [0017]      FIG. 2  is a cross-sectional view taken along line  2 - 2  of  FIG. 1 . 
           [0018]      FIG. 3  is an elevation view, in partial cross section, of an ice bin with an integral ice crusher. 
           [0019]      FIG. 4  depicts a front perspective view of another embodiment, a beverage dispenser with an integral ice crusher. 
           [0020]      FIG. 5  is an exploded view of an ice crusher with a driven blade and a non-driven blade. 
           [0021]      FIG. 5   a  is a perspective view of a second ice crusher embodiment. 
           [0022]      FIG. 6  is a front perspective view of another embodiment, an ice crusher integrally mounted on a beverage dispenser with a second dispenser for cubed ice. 
           [0023]      FIG. 7  is a plan view of the internal elements used in the ice crusher of  FIG. 5 . 
           [0024]      FIG. 8  is a side view of the internal elements used in the ice crusher of  FIG. 5 . 
           [0025]      FIG. 9  is a side view of a rotating blade with an interface for a drive shaft used in the ice crusher of  FIG. 5 . 
           [0026]      FIG. 10  is a perspective view of a bushing for a rotating blade with an interface for a drive shaft used in the ice crusher of  FIG. 5 . 
           [0027]      FIG. 11  is a perspective view of a non-rotating blade having a wiper element used in the ice crusher of  FIG. 5 . 
           [0028]      FIG. 12  is a perspective view of a bushing for a non-rotating blade used in the ice crusher of  FIG. 5 . 
           [0029]      FIG. 13  is a plan view of a drive shaft and interface for the ice crusher of  FIG. 5 . 
           [0030]      FIG. 14  is schematic diagram of an electrical system for an ice crusher and combined ice and beverage dispenser of  FIG. 4 . 
           [0031]      FIG. 15  is a schematic diagram of an electrical system for an embodiment of an ice crusher with an ice dispenser as used in the ice crusher of  FIG. 1 . 
           [0032]      FIG. 16  is a flowchart depicting steps of a method of operating an ice crusher with an ice dispenser or an combined ice and beverage dispenser. 
           [0033]      FIG. 17  is a schematic diagram of the water system of a beverage dispenser with a cold plate heat exchanger. 
           [0034]      FIG. 18  is a partial exploded view of another embodiment of a combined ice and beverage dispenser, having a single dispensing chute for both cubed and crushed ice. 
           [0035]      FIG. 19  is an enlarged perspective view of a portion of the combined ice and beverage dispenser of  FIG. 18 . 
           [0036]      FIG. 20  is a vertical cross-sectional view through the cubed ice outlet on the combined ice and beverage dispenser of  FIG. 18 . 
           [0037]      FIG. 21  is a vertical cross-sectional view through the ice crusher and crushed ice outlet on the combined ice and beverage dispenser of  FIG. 18 . 
           [0038]      FIG. 22  is a schematic diagram of an electrical system for the combined ice and beverage dispenser of  FIG. 18 . 
           [0039]      FIG. 23  is an exploded view of another embodiment of a combined ice and beverage dispenser, having separate dispensing chutes for cubed and crushed ice. 
           [0040]      FIG. 24  is an enlarged perspective view of the left-hand portion of the combined ice and beverage dispenser of  FIG. 23 . 
           [0041]      FIG. 25  is a schematic diagram of an electrical system for the combined ice and beverage dispenser of  FIG. 23 . 
           [0042]      FIG. 26  is an exploded view of the motor and rotary solenoid for the ice crusher on the combined ice and beverage dispenser of  FIG. 23 . 
           [0043]      FIG. 27  is an exploded view of the internal elements of the ice crusher used on the combined ice and beverage dispensers of  FIG. 18  and  FIG. 23 . 
           [0044]      FIG. 28  is an exploded view of the housing of the ice crusher used on the combined ice and beverage dispensers of  FIG. 18  and  FIG. 23 . 
           [0045]      FIG. 29  is an enlarged perspective view of the crushing blades used in the ice crusher of  FIGS. 27 and 28 . 
           [0046]      FIGS. 30-34  are perspective views of the components used in the ice crusher of  FIGS. 27 and 28 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0047]    The terms “cubed ice” and “ice cubes” as used herein and in the claims refers to ice frozen in a piece, regardless of its shape. Ice cubes can be rectangular in shape, round, or of some other shape. 
         [0048]    There are many embodiments of this invention. Preferred embodiments include an ice dispenser with an ice crusher that dispenses and crushes ice ( FIG. 1 ), and combined ice and beverage dispensers with an ice crusher. In this later category there are three types of equipment: those that dispense both crushed and cubed ice through the same ice dispensing chute ( FIG. 4  shows one embodiment of this type and  FIGS. 18-22  show another embodiment of this type), those that dispense crushed and cubed ice though different dispensing chutes ( FIG. 6  shows one embodiment of this type and  FIGS. 23-26  show another embodiment of this type), and those that dispense only crushed ice (not shown in any particular figures). 
         [0049]    While other types of ice crushing mechanisms may be used, in general the above embodiments envision an ice crusher with one or more crushing blades rotating in a vertical plane. The ice crusher may be designed and mounted so that the vertical plane is perpendicular to, or parallel with, the front of the dispenser. The ice may thus travel in a straight, downward line from the ice bin to the crusher to a dispensing chute and into a cup of a user. In other embodiments, the ice may make a right-angle turn from the ice bin into the ice crusher, or may make a right angle turn from the ice crusher or crushed-ice holding area into a dispensing chute. In addition, other embodiments include designing and mounting the ice crusher so that the crushing blades rotate in a horizontal plane, with ice entering from one side and leaving from an opposite side, and then making a downward turn into a dispensing chute. 
         [0050]    In the preferred embodiments, the crushing device is placed between the ice outlet from the bin and the top of the ice dispensing chute. To accomplish this, the crusher may lift ice as well as perform the crushing action. The drawings generally depict an ice crusher with a rotating set of breaker bars (rotating blades or cutters) that lift the ice as well as push it against another set of bars (non-rotating bars or cutters), which are stationary, held in place by grooves in the crusher housing. As the ice passes through the stationary bars, wipers on the stationary bars block the path of the ice and direct the crushed ice to the ice crusher housing outlet, which may include a holding area from which crushed ice is dispensed, as discussed below. In those embodiments, the crushed ice sits in a downward-angled chamber, which is closed off by a door that opens to allow ice to be dispensed. Below the door is a catch device, which collects melting ice particles and water droplets and moves them toward a drain so unsightly dripping does not occur from the ice dispensing chute. 
         [0051]    Ice crusher embodiments of the present invention may be used in ice dispensers and may also be used in beverage dispensers, particularly beverage dispensers that include an ice bin or an ice bin with an integral ice maker.  FIG. 1  depicts an exploded view of an ice dispenser  10  with an ice crusher  18 . Ice dispenser  10  includes a housing  14  and a housing cover  11 , along with a front fascia  13 . The ice dispenser includes an ice bin  12 , and a downward sloping ice opening chute  17  that interfaces with the ice crusher  18 . The ice crusher crushes and may hold ice in a small holding chamber until a user calls for ice by activating an actuator, such as the actuation lever  15 . A controller (not shown) for the ice dispenser then opens an outlet door (not shown) to the ice holding chamber, and crushed ice tumbles from the holding chamber through ice chute  16  and into a cup or container held by the user. A drip pan or catch device  19  underneath the ice crusher or underneath the chute may collect melting ice particles and water droplets, as well as spills from overfilling of cups and move them toward a drain. For clarity, the usual ice-conveying paddlewheel inside the ice bin and the motor for driving the paddlewheel are not shown. 
         [0052]    One unique aspect of the ice crusher helps to meet the area and height restrictions mentioned above. Because of these restrictions, it would be very helpful if the ice crusher could be inserted between the ice bin and the ice chute without requiring an increase in height of the ice dispenser, or a beverage dispenser when the ice crusher in included therewith.  FIG. 2  is a cross-sectional elevational view of the interfaces between an ice bin  12  and an ice opening chute  17  in a dispenser for ice or in a combined ice and beverage dispenser.  FIG. 3  is a partial cross-sectional elevational view showing the height relationships between an ice bin  12 , an ice opening chute  17 , and an ice crusher  18 . The internal working parts of the ice crusher are shown in  FIG. 5 . 
         [0053]    In  FIG. 2 , an ice opening chute  17  is assembled to an ice bin  12  at downward angle A. Angle A may be any suitable angle, but is preferably from about 10° to about 30°. This angle has been found to allow ice from the ice bin to quickly flow into the ice crusher.  FIG. 3  depicts the height relationships between the component parts of the ice crusher  18  and ice opening chute  17  and ice bin  12 . The ice resides in the ice bin  12 , preferably atop a cold plate (not shown) for cooling water and syrup for beverages dispensed by a combined ice and beverage dispenser embodiment. Ice is conveyed from bin  12  to ice chute  17  by paddlewheel  12   a  driven by motor  12   b . Ice enters the chute  17  and falls into the ice crusher  18  and working chamber  18   a . The ice is crushed and is preferably, but not necessarily, conveyed upwardly to a holding chamber  18   b . Holding chamber  18   b  is separated from the working chamber  18   a  by a wall  18   c  that, in preferred embodiments, requires the ice crusher to elevate the ice to at least as high of a level, and preferably a higher level, than the level at which the ice entered the ice crusher. Since the ice crusher lifts as well as crushes the ice, there is no need to raise the ice bin to a higher level or, alternately, to lower the outlet  16  for ice from the ice dispenser (see  FIG. 1 ). The bottom of chamber  18   b  is preferably above the lowest point of ice opening chute  17 , or the bottom of chamber  18   b  may be above some point of ice opening chute  17 . The holding chamber need not be large. In one embodiment, the chamber holds about three ounces of crushed ice. This quantity is sufficient to allow ice to begin to flow almost at once when the user activates the ice actuator. In other embodiments, ice is crushed and conveyed so quickly that a holding chamber is not necessary. 
         [0054]    As mentioned above, the ice crusher may be used in beverage dispensers as well as ice dispensers. An example of a beverage dispenser is depicted in  FIG. 4 . Beverage dispenser  20  includes housing  20   a  and top cover  20   b . The front fascia has been removed for easier observation of the relevant internal portions of the beverage dispenser. Ice is held in ice bin  21 , which interfaces through a downward sloping ice opening chute (not depicted in  FIG. 4 ) to ice crusher  22 . Ice crusher  22  is driven by motor  23  for crushing ice and delivering ice to a user via dispensing chute  24  when the user actuates ice dispensing. In this embodiment, the user has two options, crushed ice from ice crusher  22  or cubed ice. The user may select cubed ice by pressing switch  25   a , or crushed ice by pressing switch  25   b , and then begins dispensing the selected ice by pressing the dispensing chute  24 . If cubed ice is selected, door  29  may be opened when the usual paddlewheel in ice-bin  21  is actuated, and ice is dispensed through door  29  and dispensing chute  24 . 
         [0055]    The beverage dispenser preferably includes at least one valve  26  (which will generally be a mixing and dispensing valve for mixing a syrup and water and dispensing a beverage, as is well known in the art), beverage dispensing actuator or lever  27 , and dispensing nozzle  28 . The beverage dispenser typically includes a cooling system, sources of water and carbonated water, and one or more beverages or beverage syrups. The user accesses a beverage through valve  26  and nozzle  28  by actuating an actuator  27  for dispensing a beverage. 
         [0056]    The ice crusher used in either the ice crusher and dispenser  10  or the combined ice and beverage dispenser  20  is depicted in greater detail in an exploded isometric view in  FIG. 5 . The ice crusher is of relatively simple construction, and is preferably made with a nylon housing, stainless steel blades and wipers, and acetal bearings and bushings. The ice crusher  50  includes a housing  51 , an aperture  53  for mounting a driven shaft  52 , a working chamber  58  for housing the internal parts and in which the crushing takes place, and a removable door  57  so that the working parts and the internal portion of housing  51  may be cleaned. The outlet aperture and exit door or aperture for the ice is not shown in this view. Within the crushing chamber of the ice crusher are stationary blades  54  and rotating crusher blades  55 , of which only one of each is shown. The stationary blades preferably alternate with the rotating blades. The rotating blades are driven by a motor and drive shaft (not shown) powering a driven shaft  52 . One or more bearings or bushings  56  are provided to support the blades on the driven shaft  52  within the ice crusher. 
         [0057]    A beverage dispenser with an ice crusher is depicted in  FIG. 6 . Beverage dispenser  30  includes an ice crusher  31  for crushing ice and also includes separate outlets  32   a ,  32   b  for dispensing ice from the ice dispenser: dispensing crushed ice from outlet  32   a , and cubed ice from outlet  32   b . Dispensers that dispense only ice and no beverage may also have separate outlets for cubed ice and for crushed ice. Beverage dispenser  30  also includes an additional chute  17  for dispensing cubed ice or other ice held in ice bin  12 . The cubed ice is dispensed in cubed ice outlet  32   b.    
         [0058]    Ice bin  12  holds ice delivered either from an ice maker positioned above the ice bin or from another source, such as ice poured in by bucket. Ice crusher  31 , which is the same as ice crusher  50  depicted in  FIG. 5 , is driven by a motor  31   a  powering a shaft  36  on which the rotating blades are mounted. In this embodiment, ice crusher  31  has a left side  33  which may be removed for cleaning, along with the internal components. The outlet door, which would normally seal ice outlet  34 , has been removed in this view, which reveals a portion of the inside of the ice crusher. Internal wall  35  separates the working chamber  30   a  (toward the rear in this view) from the ice storage chamber  30   b  in the front. As mentioned above, the ice may be lifted from the working chamber in order to clear the internal wall and reach the storage chamber. Typical beverage dispensers also include at least one valve  37 , at least one nozzle  38 , and at least one actuator  39  for dispensing a beverage. 
         [0059]    In the embodiment shown in  FIG. 6 , ice travels downward from ice bin  12  into ice crusher  31  and then outwardly to chamber  30   b . Then, when the exit door (not shown) to the crushed ice chamber opens, the ice makes a 90° horizontal turn in order to exit and fall into the beverage cup of a user. In embodiments not requiring a storage chamber, there may be no reason for a 90° horizontal turn. In such embodiments, as shown in  FIG. 5   a , ice crusher  81  may simply have a gate or a door, such as a guillotine door (not shown), to an exit area  87  from crushing chamber  82 . When the user activates a switch for crushed ice, the ice flows from bin  12  in the rear area  86  of crusher  81 . At the same time, the crusher is actuated and crushes ice almost instantaneously, while the door opens and ice is dispensed quickly. 
         [0060]    The internal workings of the ice crusher are very important, because they need to be clean and sanitary as well as effective at crushing and conveying ice. The internal elements of ice crusher  40  mounted to removable left door  41  are depicted in  FIG. 7 . In this embodiment, the ice crusher interfaces through driven shaft  42  with the motor, located in the beverage dispenser or ice dispenser. Ice crusher  40  includes three internal rotating blades  43  alternating with four internal stationary blades  44 . Each blade preferably has at least one bushing  45 ,  48  to minimize wear during rotation. The stationary blades are mounted on driven shaft  42 , and as shown above, are not interfaced for being driven by drive shaft  42  and are prevented from rotating by the design of the ice crusher housing. In embodiments with a plurality of rotating/non-rotating blades, the blades are preferably assembled in an alternating manner, as shown in  FIG. 7 . 
         [0061]    The wiper portion  44  on the non-driven blades will tend to wipe crushed ice from the rotating blades and cause the crushed ice to be transported through the outlet. Wiper portion  44  is bent at an angle of about 90° to the plane of the stationary blade, so that the wiper portion will fill most of the gap between adjacent rotating blades. A clearance of about 0.040-0.050 inches (about 1 mm) is recommended. If the ice crusher has a storage chamber and door, the ice will be stored before it is dispensed. If the ice crusher does not have an integral storage chamber and remotely-actuatable door, the ice will flow from the outlet of the crushing chamber to a dispensing means or storage volume as provided. 
         [0062]      FIGS. 8-13  provide additional views of the internal components of the embodiment of the ice crusher depicted in  FIG. 5 . These components, and components very similar to them, may also be used in many of the other embodiments. A side view is presented in  FIG. 8 . As will be seen in  FIGS. 9 and 10 , the rotating blades  43  are mounted fixedly to the drive shaft  42  by a gear design on the inner periphery of the rotating blades and bushings  45  that matches the design on the outer periphery of shaft  42 . When the shaft rotates, rotating blades  43  and bushings  45  rotate in tandem with the shaft. The bushings also act as vibration and sound dampening devices. 
         [0063]    The drive shaft, in this embodiment, interfaces with a motor through dog-teeth on one end of the shaft. Rotating blades  43  are straight with a central hub and with cutting or crushing features such as teeth  43   a  on all four surfaces of each rotating blade. Non-rotating blades  44  preferably also have cutting or crushing features such as teeth  44   a  on at least one surface of the blade in this embodiment, although this feature is not necessary for their function of wiping and clearing ice from the crushing portion. The non-rotating blades also have a central hub and two portions, one portion on one side of the central hub with a cutting or crushing feature  44   a , and another portion  44   b  at an angle of about 120°. Portion  44   b  includes a wiper  44   e  bent at about a 90° angle to a plane of non-rotating blade  44 . In the orientation as seen in  FIG. 8 , the rotating blades rotate clockwise, so that ice is crushed by force generated between teeth features  43   a  on rotating blades  43  and teeth features  44   a  on non-rotating blades  44 , and ice is wiped off the rotating blades and falls back downward away from wiper  44   e.    
         [0064]    The interface between rotating blade  43  and bushing  45  is depicted in  FIGS. 9 and 10 . Bushing  45 , preferably made from acetal, includes an outer periphery  45   a  and notches  45   b  so that blade  43  can lay flat in the bushing. While acetal is preferred, any other food-grade material that is resistant to wear and erosion in sliding contact will suffice. These other materials include at least PTFE and nylon. The bushings also include bosses  46  that fit into apertures  43   b  in rotating blade  43 . These bosses force bushing  45  to rotate with rotating blade  43 . Bushing  45  also has a drive design on its inner periphery  47 , including gaps  47   a  and raised portions  47   b  for interfacing with a drive shaft. Rotating blade  43  has a similar inner periphery of slightly larger diameter, so that bushing  45  can be assembled with rotating blade  43 , and blade  43  and bushing  45  will rotate together. 
         [0065]      FIGS. 11-12  depict the non-rotating or stationary blade  44  and its bushing  48 . Blade  44  preferably is made from stainless steel and has a first portion with tooth  44   a  for crushing or breaking ice and a retainer  44   d  for interfacing with the ice crusher housing. Relief  44   c  allows retainer  44   d  to fit into a groove in the housing. Blade  44  has a second portion  44   b  that is bent at about 90° to the plane of the blade so that wiper portion  44   e  can wipe away ice from between rotating blades  43  to provide a ready supply of crushed ice while allowing the blades to continue to rotate. The central area  44   g  has a plurality of apertures  44   f  for receiving bosses  48   a  from bushing  48 . The bosses  48   a  are preferably in a different pattern from the pattern of rotating bushing  45 , and the diameter of inner periphery  48   b  is preferably different and larger from the inner periphery of bushing  45 , so that the bushings  45 ,  48  cannot be assembled with the incorrect blade. Bushings  48  function as bearings for non-rotating blades  44  on the outside of shaft  42  ( FIG. 13 ), while bushings  45  are assembled with rotating blades  43 , so that the blade  43  and bushing  45  assemblies interface with shaft  42 . 
         [0066]      FIG. 13  depicts one embodiment of a shaft  42  for use in this embodiment. Shaft  42  is a driven shaft that interfaces by means of dog-teeth  42   a  to driving shaft  49  and dog teeth  49   a . Dog-teeth  49   a  may be held by a pin  49   b  as shown. 
         [0067]      FIG. 14  depicts an electrical system for an embodiment of an ice crusher and combined ice and beverage dispenser. The electrical system includes components for a combined ice and beverage dispenser with a carbonation system and an ice crusher. The electrical system  60  for this dispenser includes a power source  61 , which may be single phase 120VAC, or may be power of another voltage. In other embodiments, three-phase power may be used for the beverage dispenser or for the ice crusher, or for both. 
         [0068]    The electrical system includes a first circuit board  62  and a carbonator circuit board  64 . Circuit board  62  mounts mounting hardware or plugs  65  and a microprocessor controller  66  for controlling the drink dispenser with an integral ice crusher. The electrical system controls power to the soda valves and to the coils of ice crusher motor  63 . Microprocessor controller  66  interfaces with safety switches and interlocks (not shown) on the dispenser. Interlocks may guard against removal of safety panels of a housing of the ice and beverage dispenser, by interrupting power to the ice and beverage dispenser if the panels are removed. Interlocks may also be placed on other components of the dispenser, including the ice crusher motor  63 . A current transformer  69  may insure that ice crusher motor  63  is not overloaded by shutting down power to ice crusher motor  63  in case of an overload. 
         [0069]    Ice dispensing switch  70 , activated by an actuator for ice crusher motor  63 , may interface with microprocessor controller  66  to begin crusher motor  63  when a user wishes to dispense ice, and afterwards to stop the crusher motor. Circuit board  62  may also mount transformers  71 ,  73 , for providing stepped-down voltages to useful voltages, such as transformer  71  for providing 5V for control purposes and transformer  73  for providing 12V or 24VAC for beverage valves. Wiring harness  77  may provide 24V power to a conversion circuit  78  for powering solenoids  79  for solenoid valves or for the solenoid door for the ice crusher. Shielding  80  may be provided for power lines to and from transformers  71 ,  73 . The shielding may be separated, such as for power harness  77  and for control circuitry, such as for the circuit board  62 . 
         [0070]    Circuit board  64  may contain controls for operating a carbonator for the ice and beverage dispenser. Included may be relay  85  for providing power to a carbonator motor pump. There may also be controls  83 , such as a microprocessor, for receiving a signal from a carbonator lever sensor. Controls  83  may respond to a carbonator level sensor high and low level signals to supply or stop water to the carbonator. There may also be a circuit (not shown) for providing power and control for the typical paddlewheel type ice agitator within the ice bin, and its motor. The unit also has a safety switch, also known as a kill switch  67 , to prevent operation if the cover is removed. 
         [0071]    A simplified control system  90  for an embodiment of an ice dispenser with an ice crusher is depicted in  FIG. 15 . Control system  90  includes a power source  91   a , transformers  92 ,  93  and a microprocessor controller  94 . The transformers may include a first transformer  92 , for stepping down input power to a voltage suitable for an ice crusher motor  96 . Transformer  93  may be suitable for stepping down input power to a control voltage, such as 5 VDC, for operating microprocessor controller  94 , and for relays and solenoids. 
         [0072]    Control system  90  may also include controls for a switch or an actuator  91   b  for turning on the ice crusher. When the ice crusher is activated, relays  95  and  98  may activate for as long as actuator  91   b  is actuated, or for a specific period of time, such as for 3-20 seconds. Other periods of time may be programmed into the microprocessor controller. During operation, a current transformer  97  may be used to monitor the current drawn by the ice crusher motor. If the current is above a certain limit, controller  94  may be programmed to trip relay  95 , thus cutting power to the motor. If this happens, the controller may also be programmed to trip relay  98 , thus closing the solenoid door from the ice crusher to the ice chute down stream from the ice crusher, or the chamber which connects to the ice chute. 
         [0073]      FIG. 16  is a flow chart for a method  101  of operating an ice crusher which is used in an ice dispenser or in a combined ice and beverage dispenser. In this method, a user depresses an actuator  110  in order to activate the ice or combined ice and beverage dispenser to dispense ice. Actuation also results in starting an agitator motor within the ice bin, such as a motor for a paddlewheel, thus bringing ice to the chutes within the ice bin, including the crushed ice chute. After actuation, the ice solenoid door opens  120 , dispensing ice that remains if there is a holding chamber for a small amount of previously-crushed ice. Alternatively, as seen in the dispenser of  FIGS. 18-22  and the dispenser of  FIG. 23-26 , the door can be on the outlet of the ice crusher. The ice crusher also activates  130 , starting the ice crusher motor. The rotating blades of the ice crusher rotate  140 , crushing ice against the non-rotating blades. The non-rotating blades wipe  150  ice from the rotating blades. By this action of the rotating and non-rotating blades, ice is conveyed  160  to a chamber down-stream of the crushing chamber. Alternately, ice is conveyed  170  out of the ice crusher to an ice chute. The ice crusher then stops  180 , either deactivated by the user ceasing to depress an actuating button or pad, or ceasing to push on an actuating lever. Alternatively or additionally, the ice crusher may be programmed to cease after a specified period of time. The exit door, preferably a solenoid-operated door, then closes, and the ice crusher/dispenser is ready for the next user. 
         [0074]    The ice bin and beverage dispenser embodiments preferably do not depend on mechanical refrigeration, except, as discussed above, embodiments that include an integral ice maker. The term mechanical refrigeration includes machinery, such as electrically-powered or gas-powered refrigeration systems, but does not include a quantity of ice without such machinery. The term “non-refrigerated ice bin” therefore refers to an ice bin that is not inside of a refrigerated space, such as the ice bins depicted herein, wherein the ice melts over time and has to be replenished. By way of contrast, an ice bin inside of a freezer compartment of a home refrigerator/freezer appliance is a refrigerated ice bin. 
         [0075]      FIG. 17  depicts portions of the beverage system in a combination ice and beverage dispenser. The beverage system may be the same as beverage systems currently used in beverage dispensers, and is therefore not discussed in detail. In the depicted embodiment, there are ten mixing and dispensing valves  190 . The number of valves may vary from one model of equipment to another. In the ice and beverage dispenser having twenty mixing and dispensing valves, two separate systems like that of  FIG. 17  will be used in one machine. A water manifold  192  is used to supply carbonated or non-carbonated water to the valves  190 . Non-carbonated water is used to provide a non-carbonated “water only” beverage through one or more of the valves  190 . One such manifold is depicted in U.S. Pat. No. 6,698,621, incorporated herein by reference. In this embodiment, water is supplied to and cooled by cold plate  196 . The cold plate typically sits at the bottom of the ice bin, and is cooled by the same ice that is dispensed from, or fed to the crusher, from the ice bin. Plain water is fed from the cold plate to both a carbonator  194  and the manifold  192 . A carbon dioxide line (not shown) provides carbon dioxide to the carbonator  194 . Carbonated water is then fed to the manifold  192 . Cold plate heat exchanger  196  is preferably made by casting aluminum around one or more coils for cooling water or syrup. Other details of a typical beverage system, such as a carbonator pump, water lines, syrup lines and the like, are depicted in U.S. Pat. No. 6,761,036, which is also incorporated herein by reference. 
         [0076]      FIGS. 18-22  depict a preferred embodiment of a combined ice and beverage dispenser  210 . The dispenser  210  is very similar to dispenser  20  of  FIG. 4 , but includes several significant modifications. First, in this embodiment the opening out of the ice bin to the ice crusher  250  is always open. However, ice cubes will not pass through the ice crusher unless the door out of the ice crusher is open and the crusher is activated. Second, there is no holding chamber for crushed ice. 
         [0077]    As shown in  FIG. 18 , a front fascia  213  normally covers the ice crusher and motor. The beverage mixing and dispensing valves  226  have been left out of  FIG. 18  for clarity, but are shown in  FIG. 19 , where the fascia  213  is not shown for clarity. There are two openings out of the ice bin, opening  212  for cubed ice, and opening  217 , which feeds into the ice crusher housing. Also seen in  FIG. 18  is a recess  215  that allows the ice crusher and motor components to be set back, reducing the amount that they protrude from the front of the machine. Opening  212  is normally closed by door  214 , which is operated by lever arm  218  connected to rotary solenoid  216 . The door  214  slides up and down in tracks provided in the opening  212 , which are at a slight angle from vertical. When door  214  is open and the paddlewheel inside the ice bin is rotating, ice cubes pass through opening  212  into collector  222  which is formed on the top of dispensing chute  224 . The ice crusher housing has an outlet normally covered by door  234 , which is operated by lever  232  connected to rotary solenoid  230 . A safety guard  235  (best seen in  FIG. 19 ) is mounted on a rod inside of collector  222 . The guard is pivotally mounted so that its bottom can swing away from the ice crusher, allowing crushed ice to pass into the dispensing chute  224 . However, the guard can only swing back to the vertical position, where it stops, which prevents someone from sticking a finger up into the chute and getting it in contact with the internal crusher elements. 
         [0078]      FIG. 20  shows a cross-sectional view of the cubed ice outlet for dispenser  210 . In this view, the slot  211  in which door  214  slides can be easily seen. (The door  214  is not shown in this view for sake of clarity.) As noted earlier, this slot is at a slight angle from vertical. 
         [0079]      FIG. 21  shows a cross-sectional view of the crushed ice outlet and ice crusher for dispenser  210 . This view also shows the paddlewheel  260  used to lift ice within the ice bin  262  of dispenser  210 . The cross-section is slightly to the right of center through the paddlewheel. 
         [0080]    Cubed ice is delivered to ice crusher  250  through a downward sloping chute. Rotating crusher blades  255  turn counter-clockwise in the view of  FIG. 21 , crushing the ice cubes against stationary blades  254  at about the 5 O&#39;clock position. The crushed ice is then carried up inside the crusher housing until it spills over through the crusher housing outlet when door  234  is lifted by rotary solenoid  230 . Any crushed ice that stays on rotating blades  255  is wiped off by the wipers on stationary blades  254 .  FIG. 21  also shows the location of merchandiser light  264 . 
         [0081]    A keypad selector  240  ( FIG. 19 ) is used to select whether cubed or crushed ice is to be dispensed. If button  241  is pushed, crushed ice will be dispensed when the dispensing chute  224  is pushed backward. If button  246  is pressed, then cubed ice will be dispensed when dispensing chute  224  is pushed. 
         [0082]    The control of the rotary solenoids  216  and  230 , and the crusher motor  223 , as well as other electrical components, is performed using an electrical system, the schematic of which is depicted in  FIG. 22 . Circuit board  244  includes terminals for several circuits, as well as a microprocessor controller. For example, P 1  and P 2  connect to line voltage power. The wires leading to a rectifier supplying power to rotary solenoid  216  used to control the dispensing of cubed ice connect to the circuit board  244  at P 9  and P 10 . Likewise, wires to the rectifier supplying power to rotary solenoid  230  used to open the door  234  leading out of the ice crusher  250  connect at P 5  and P 6 . Crusher motor and its associated capacitor connect through P 3  and P 4 . Keypad  240 , containing selector pushbuttons  241  and  246  for selecting crushed or cubed ice, connect to the circuit board  244  through a ribbon cable  243  having a polarized plug at J 1 . Reduced voltage power for operating mixing and dispensing valves  226  (the control circuitry of which is standard and therefore not shown) is provided by transformer  280 , which also supplies low voltage power to circuit board  244  at J 4 . The schematic also shows power being supplied to fluorescent light  264  and its associated ballast and starter. The dispenser  210  is equipped with a kill switch  272  which shuts down power to the machine when the front cover is removed. Dispense switch  274 , connected to circuit board  244  at J 3 , is activated when the dispensing chute  224  is pushed. The motor  276 , connected to the circuit board through P 7  and P 8 , operates the paddlewheel. The control system is set up such that when the dispense switch  274  is activated, motor  276  rotates, and the microprocessor looks to see which of pushbuttons  241  and  246  was last pressed. If pushbutton  241  was last pressed, the crusher motor  223  and crusher solenoid  230  are activated simultaneously, causing the crusher to operate and opening door  234  adjacent the crushed ice outlet. If pushbutton  246  was last activated, the cubed ice solenoid  216  is activated, opening door  212 . 
         [0083]    Ice and beverage dispenser  310  of  FIGS. 23-26  has separate cubed ice and crushed ice dispensing chutes, like dispenser  30  of  FIG. 6 , but includes several significant modifications, many of which are similar to features on dispenser  210  of  FIGS. 18-22 . As with  FIG. 19 , the front fascia is not shown for dispenser  310 . The dispenser  310  is shown with two paddlewheel areas  362  and  363 . These paddlewheel areas each contain a paddlewheel, one for supplying ice to the ice crusher, and one for supplying ice to the cubed iced dispensing chute. 
         [0084]    The cubed ice dispensing chute  361  is located on the right side of dispenser  310 . The flow of cubed ice through the outlet from the ice bin is controlled by pushing cubed ice dispensing chute  361 . The connection of dispensing chute  361  to the dispenser  310 , and the control of ice cubes through the chute, may be the same as the cubed ice dispensing mechanism on a conventional ice and beverage dispenser that only dispenses cubed ice, or it may include a rotary solenoid and a door like the solenoid  216  and door  214  of dispenser  210 . 
         [0085]    The design of the ice crusher  350 , motor  323 , rotary solenoid  330 , door  334  and arm  332  on dispenser  310  is the same as the corresponding parts on dispenser  210 . Likewise, the control of these components is essentially the same.  FIG. 25  shows a circuit diagram for the dispenser  310 . Many components are the same as the schematic diagram of  FIG. 22  for dispenser  210 . Since the dispenser  310  has two paddlewheels in areas  362  and  363 , there are two motors, left motor  376  and right motor  377 , for powering the paddlewheels. There are also two transformers  380 , each supplying low voltage power to a separate set of mixing and dispensing valves  326 . Switch  375  is activated when the cubed ice dispenser is pushed, which then activates right motor  377 . There are also optionally two merchandiser lamps  364 , with associated ballasts  383  and starters  385 . The capacitor  386  and relay  387  for the crusher motor are shown in  FIG. 25 . These items, and a few additional unnumbered items, such as nuts, screws, washers, mounting brackets, a timer, electrical box, and other minor items, are shown in the exploded views of  FIGS. 23 and 26 .  FIG. 25  also shows the switch  371  that gets activated when dispensing chute  324  or optional lever  372  is pushed, pivoting on rod  373 ; the kill switch  374  (also shown in  FIG. 26 ); and optional agitator timers  388  that can be included to rotate the paddlewheels if no one dispenses ice for a predetermined amount of time, thus keeping ice cubes in the bin from sticking together. 
         [0086]    Detailed and exploded views of the ice crusher  250  and its components are shown in  FIGS. 27-34 . Ice crusher  350  used on the combined ice and beverage dispenser  310  is just the same as ice crusher  250 . Many of the pieces of ice crusher  250  are very similar to those used in the ice crusher  50 , such as the stationary bushing (spacer)  248  and the rotating bushing (spacer)  245 , and will therefore not be explained again in detail. Some of the more significant differences, however, are as follows. As noted earlier, the housing  251  for the ice crusher  250  does not include a holding chamber. The shape of the wiping section on non-rotating blades  254  is slightly different. The removable door  257  has a different shape, and includes a tab  290  that can be grasped to detach the door  257  from the rest of the housing  251  by rotating the door 5° counter-clockwise. When the door is put on, a living hinge allows detents to snap it into place. A gasket  292  is provided to help seal the door  257 . The housing  251  includes guides  294  in which the outlet door  234  slides up and down. Drive shaft  249  and driven shaft  242  interface differently, using a protruding pin  247  in the drive shaft, rather than dog teeth. A spring wave washer  291  is provided between the last stationary bushing and the door  257 . Bushings  296  and seals  297  are provided on the outside of door  257  ( FIG. 27 ) and inside the housing  251  against the outer wall ( FIG. 28 ). Retaining rings  295  are used to hold the assembly together. The blades  254  and  255  thus come out of the housing  251  with the door when the door  257  is removed. 
         [0087]    The present invention may be applied to existing ice dispensers or existing combined ice and beverage dispensers. Particularly, the preferred embodiments of the ice crusher designs that do not need additional height on the basic machine to accommodate them are useful for retrofitting an existing dispenser. A retrofit kit for this use will include an ice crusher and a dispensing chute. The ice crusher will be attachable to the existing dispenser, in the area where cubed ice is currently dispensed. The new ice dispensing chute will be attachable to the ice crusher. Ice crusher and chute designs described above can thus be combined to provide a retrofit kit. The ice crusher could be wired in parallel with wiring used to activate the paddlewheel motor when the ice dispensing chute is pushed. 
         [0088]    There are many embodiments of the present invention, of which only a few presently-preferred embodiments have been described. For instance, rather than using non-rotating blades to react and crush the ice as the rotating blades, the ice crusher could be made with blades or elements of fixed position molded or assembled into the housing. For purposes of this patent, such fixed elements are equivalent to a “non-rotating blade.” Instead of having wipers on the non-rotating blades, a wiper could instead be part of the rotating crusher blades. Rather than mounting the crusher as shown in  FIGS. 1 and 4 , the crusher could be mounted at a 90° angle, with the crushing blades moving in a horizontal or lateral plane, rather than vertical. Rather than using a rotary solenoid to open doors, a mechanical linkage could be used. As noted earlier, other crushing mechanisms could be used, such as a sonic crusher. It is intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to define the spirit and scope of this invention.

Technology Classification (CPC): 8