Patent Description:
Ice bins are used to receive ice from an ice maker and store the ice until the ice is used. Ice bins often include a scoop for retrieving ice stored out of the bin without direct contact between ice and the user's hands. Scoops are typically placed on top of the ice when not in use. By putting an ice scoop on top of the ice, the scoop has a tendency to become cold to the user's touch, especially if the scoop has been in the bin for a significant amount of time. Further, when the scoop is placed on top of the ice during non-use, the creation of new ice has a tendency to bury the ice scoop, making it difficult for the user to find and requiring the user to dig through the ice, causing the user to become cold and potentially contaminating the ice.

<CIT> discloses an ice bin assembly for use with an ice making apparatus, the ice bin comprising an ice storage cavity and an ice access opening, a door attached to the ice bin over the ice access opening, a pin attached to one of the ice bin and the door, wherein the pin has a cavity opening onto an outer surface. A resilient material is disposed within a cavity to bias a locking element outward therefrom, and a channel member is attached to the other of the ice bin and the door, and the channel member receives the pin and has a first aperture sized to receive the locking element.

<CIT> discloses a scoop retention device comprising a first length of flexible tubing having openings at each of first and second ends, the first length of tubing being configured to receive and retain a handle of a scoop within the first opening, a first magnet secured within the opening at the second end of the first length of tubing and having an exposed surface associated with a first magnetic polarity, and a second magnet securable to the inside of a container having a surface associated with a second magnetic polarity opposite the first polarity and facing the inside of the container, such that the scoop is removably secured to the inside of the container by magnetic attraction between the first and second magnets.

<CIT> discloses a thermally insulated enclosure comprising an insulated wall and a magnet assembly coupled to it, for mounting the insulated enclosure to ferromagnetic structures.

<CIT> discloses an enclosure having an ice storage room for storing ice generated in an ice making section, wherein one side of the enclosure is open to the ice from the storage room; an ice making machine comprising an outlet, a door disposed in the housing and capable of opening and closing the outlet; a scoop for taking out stored ice; a magnet provided on one of the doors; a magnet used for the other, or a magnetic body; and a scoop holding structure which is detachably held on the inner surface of the door by magnetic attraction.

<CIT> discloses an adjustable measuring scoop comprising a partition that is movable so as to result in a scoop size that can be selectively determined between a maximum and a minimum by ready manual manipulation of the scoop.

<CIT> discloses a shovel keeping mechanism in an ice making machine provided with an ice storage bin placed under an ice making mechanism to store ice cubes dropped therefrom, wherein the shovel keeping mechanism comprises a pair of parallel support rail portions provided on the bottom surface of a component member located at a lowermost portion of the ice making mechanism, and extended in a fore-and-aft direction of the ice storage bin, and a shovel holder detachably assembled with the parallel support rail portions to retain an ice shovel inserted therein from the front of the ice storage bin.

Further relevant prior art is disclosed in document <CIT>.

The present invention is disclosed in the independent claims.

An ice bin according to claim <NUM> comprising a bin body is disclosed. The bin body comprises a lower portion, an upper portion, and a perimeter wall extending height-wise from the lower portion to the upper portion. The upper portion of the bin body defines an ice drop opening configured so that ice dropped from an ice maker supported above the ice bin is passable through the ice drop opening into the interior of the ice bin. The bin body further comprises an ice retrieval opening spaced apart from the ice drop opening for providing access to the interior of the ice bin. The perimeter wall also comprises a support plate configured to support an ice scoop on the interior of the perimeter wall by a magnetic force between the ice scoop and the support plate, wherein the ice bin further comprises an upright frame member formed from ferromagnetic material so that the ice scoop can be supported on an exterior of the ice bin by force of magnetic attraction between the upright frame member and the ice scoop.

An ice storage and retrieval assembly according to claim <NUM> comprising an ice bin according to claim <NUM> is disclosed. The ice bin comprises a bin body, the bin body comprising a lower portion, an upper portion, and a perimeter wall extending height-wise from the lower portion to the upper portion. The upper portion of the bin body defines an ice drop opening configured so that ice dropped from an ice maker supported above the ice bin is passable through the ice drop opening into the interior. The bin body further comprises an ice retrieval opening spaced apart from the ice drop opening for providing access to the interior of the ice bin. The perimeter wall comprises a support plate for supporting an ice scoop comprising at least one magnetic element. The scoop is configured to support itself on the perimeter wall at a location in the interior of the ice bin overlying the support plate by a magnetic force between the ice scoop and the support plate, wherein the ice bin further comprises an upright frame member formed from ferromagnetic material so that the ice scoop can support itself on an exterior of the ice bin by force of magnetic attraction between the upright frame member and the ice scoop.

A method according to claim <NUM> of manufacturing an ice bin according to claim <NUM> is disclosed. The method includes forming a liner and an outer shell of the ice bin, fitting the liner into the outer shell, fitting the support plate between the liner and the outer shell temporarily using an adhesive, and foaming the area between the liner and the outer shell with an insulation layer to permanently secure the support plate in position.

In another aspect, an ice maker appliance is disclosed. The ice maker appliance comprises an ice bin according to claim <NUM> comprising a bin body and a front door assembly. The front door assembly comprises a shell, a liner, and a support plate. The ice maker further comprises an ice scoop comprising at least one magnetic or ferromagnetic element.

Other objects and features of the present disclosure will be in part apparent and in part pointed out herein.

Corresponding reference numbers indicate corresponding parts throughout the drawings.

<FIG> and <FIG> show embodiments being useful for understanding the invention, which are outside the subject-matter of the claims. <FIG> shows an embodiment according to the present invention, which discloses an ice bin according to claim <NUM>.

Referring to <FIG> and <FIG>, an ice bin <NUM> with a scoop <NUM> is shown. The ice bin comprises a bin body <NUM>. The bin body is comprised of a lower portion <NUM>, an upper portion <NUM>, and a perimeter wall <NUM>. The perimeter wall <NUM> extends heightwise from the lower portion <NUM> to the upper portion <NUM>. The perimeter wall <NUM> further comprises an outer shell <NUM> and a liner <NUM>. The liner <NUM> defines an inner perimeter of the perimeter wall <NUM> and the outer shell <NUM> defines an outer perimeter of the perimeter wall. The liner <NUM> is disposed within the outer shell <NUM> and further defines an interior of the ice bin <NUM> for ice to be held for future use.

The ice bin <NUM> further defines two openings, an ice drop opening <NUM> (broadly, ice drop area) and an ice retrieval opening <NUM> (broadly, ice retrieval area). The upper portion <NUM> surrounds the ice drop opening <NUM> and is configured to form a seat. The ice drop opening <NUM> is configured so that ice formed in an ice maker (not shown), supported above the ice bin <NUM> on the seat of the upper portion <NUM>, is passable through the ice drop opening into the ice bin. Once the ice from the ice maker has passed through the ice drop opening <NUM>, it rests in the interior of the liner <NUM> for future use. The ice is then retrieved from the interior of the liner <NUM> by a user through the ice retrieval opening <NUM>. The ice retrieval opening is located generally at the front end of the ice bin <NUM>, as illustrated in <FIG>. A door <NUM> is configured to operatively open and close the ice retrieval opening <NUM>. The ice bin <NUM> is supported off of the ground using legs <NUM>.

Referring to <FIG>, the left side of the outer shell <NUM> of the perimeter wall <NUM> is removed to show the area between the outer shell and the liner <NUM>. <FIG> similarly shows the right side of the outer shell <NUM> of the perimeter wall <NUM> removed to show the area between the outer shell and the liner <NUM>. The exterior surface of the liner <NUM> on either or both of the left or right side of the liner is configured to support a support plate <NUM>.

In general, each support plate <NUM> is configured to support the scoop <NUM> on the inner wall of the bin <NUM> via a force of magnetic attraction between the support plate and the scoop. In one or more embodiments, the support plate <NUM> can comprise a ferromagnetic material such as galvanized steel and the scoop <NUM> comprises a magnetic material configured to impart a force of magnetic attraction between the ferromagnetic scoop and the support plate. In another embodiment, the support plate <NUM> comprises a magnet and the scoop <NUM> comprises ferromagnetic material such that the support plate <NUM> is configured to impart a force of magnetic attraction to the scoop for holding the scoop on the wall of the bin. Hereafter, an exemplary embodiment will be described wherein each support plate <NUM> comprises a single monolithic piece of ferromagnetic material (e.g., galvanized steel) and the scoop <NUM> comprises one or more magnets. However, it is now understood that the use of magnetic and ferromagnetic material as between the bin and the scoop be reversed without departing from the scope of the disclosure.

The support plate <NUM> is generally configured to be supported on the liner in the upper front corner of the liner <NUM>, such that the support plate is adjacent to the ice retrieval opening <NUM>. The illustrated support plate <NUM> is supported in the upper front corner of the liner <NUM> such that there is basically no spacing between the support plate and the front of the liner or the support plate and the top of the liner. This positioning allows for the scoop <NUM>, further described below, to be situated away from the ice drop path and out of the ice reservoir.

Referring to <FIG>, the support plate <NUM> has a front-to-back depth D1 defined by a distance between a back edge margin and a front edge margin (e.g., the front-most edge margin of the support plate). In one embodiment, the front-to-back depth of the support plate <NUM> is in an inclusive range of from about <NUM> to about <NUM> (e.g., from about <NUM> to about <NUM>). In the illustrated embodiment, the back edge margin of the support plate <NUM> is spaced apart from the back of the liner <NUM>. For example, in one or more embodiments (shown in <FIG> and <FIG>), the back edge margin of the support plate <NUM> is spaced apart from the back of the liner <NUM> by a front-to-back spacing distance D3 in an inclusive range of from about <NUM> inches to about <NUM> (e.g., from about <NUM> to about <NUM>). In certain embodiments, the front-to-back spacing distance is greater than the front-to-back depth D1 of the support plate. Along the front-to-back spacing distance, it is not possible for a user to support the scoop <NUM> magnetically on the inner wall of the bin. This is desirable because it prevents the user from positioning the scoop <NUM> toward the rear of the bin <NUM>, where it might interfere with falling ice. The liner <NUM> itself has a front-to-back depth D4. In one or more embodiments, the front-to-back depth of the support plate D1 is in an inclusive range of from about <NUM>% to about <NUM>% of the front-to-back depth D4 of the liner (e.g., an inclusive range of from about <NUM>% to about <NUM>%). In certain embodiments, the front-to-back spacing distance D3 is in an inclusive range of from about <NUM>% to about <NUM>% of the depth D4 of the liner (e.g., an inclusive range of <NUM>% to about <NUM>%). In the illustrated embodiment, the upper front corner region of each support plate <NUM> is beveled to match the angle of the doorframe around the ice retrieval opening <NUM>. Because of this bevel, the top edge margin of the plate <NUM> has a front-to-back depth D2 that is less than the overall front-to-back depth D1 of the plate <NUM>. In certain embodiments, the bevel front-to-back depth D2 is an inclusive range of <NUM>% to <NUM>% of the front-to-back depth D1 of the support plate <NUM>.

The support plate <NUM> has a top-to-bottom height H1 between a top edge margin and a bottom edge margin. In one embodiment, the top-to-bottom height H1 is in an inclusive range from about <NUM> to about <NUM> (e.g., from about <NUM> to about <NUM>). In the illustrated embodiment, the bottom edge margin of the support plate <NUM> is spaced apart from the bottom of the liner <NUM> by a top-to-bottom spacing distance H3 in an inclusive range of from about <NUM> to about <NUM> (e.g., from about <NUM> to about <NUM>). In certain embodiments, the top-to-bottom spacing distance H3 is greater than the top-to-bottom height distance H1. The liner <NUM> itself has a top-to-bottom height H4. In one or more embodiments, the top-to-bottom height of the support plate H1 is in an inclusive range from about <NUM>% to about <NUM>% of the top-to-bottom height of the liner H4 (e.g., an inclusive range of from about <NUM>% to about <NUM>%). In certain embodiments, the top-to-bottom spacing distance H3 is in an inclusive range of from about <NUM>% to about <NUM>% of the top-to-bottom height of the liner H4 (e.g., an inclusive range of <NUM>% to about <NUM>%). In the illustrated embodiment, the upper front corner region of each support plate <NUM> is beveled to match the angle of the frame around the ice retrieval opening <NUM>. Because of this bevel, the top edge margin of the plate <NUM> has a height H2 below the bevel that is less than the overall height H1. In certain embodiments, the height H2 is an inclusive range of <NUM>% to <NUM>% of the height H1. The beveled edge defines an angle A1 with the front edge of the plate <NUM>, measured as the outside angle between the front vertical edge and the bevel edge. In one or more embodiments, the angle A1 is in an inclusive range of from about <NUM>° to about <NUM>°.

Referring to <FIG>, disposed in the area between the outer shell <NUM> and the liner <NUM> is an insulation layer (not shown). The insulation layer is molded-in-place between the liner <NUM> and the outer shell <NUM> and around the support plate <NUM>. In one or more embodiments, the insulation layer is formed from spray foam insulation. Once molded in place, the insulation firmly holds the support plates <NUM> in position. But as explained more fully below, the illustrated bin <NUM> further comprises double sided tape (broadly, an adhesive) between the plate <NUM> and the liner <NUM> that further supports the plate on the liner, and in particular, is configured to hold the plate in place the liner prior while the foamed insulation is being molded-in-place. The insulation layer keeps the temperature inside the liner <NUM> close to or below freezing and slows the drift toward warmer ambient temperature.

Referring to <FIG>, the scoop <NUM> comprises a handle portion <NUM> and a scoop portion <NUM>. The handle portion <NUM> has a distal end and a proximate end. The scoop portion <NUM> is attached to the distal end of the handle portion <NUM>. The scoop portion <NUM> defines one or more magnetic receiving enclosures <NUM>, and a magnetic element <NUM> (broadly, a magnetic attraction element, which in the illustrated embodiment comprises an element formed from a magnetic material; but as explained above, could, in other embodiments, comprise an element formed from ferromagnetic material) is received in each enclosure. The enclosures <NUM> further comprise a cap <NUM>, such that when the magnetic element <NUM> is placed into the magnet receiving enclosure, the cap is joined to the scoop <NUM> over the open end of the magnet receiving enclosure such that the cap retains the magnetic in the enclosure. In one embodiment, the scoop <NUM> is made of plastic. It is contemplated that, in an alternative embodiment, if the bin support plates <NUM> were to comprise magnets instead of ferromagnetic material, the entire scoop <NUM> could be formed from ferromagnetic material such as galvanized steel instead of forming pockets for ferromagnetic elements. The illustrated magnetic elements <NUM> are configured to interact with the support plate <NUM> in order to support the scoop <NUM> against the interior wall of the liner <NUM> of the ice bin <NUM> in a position overlying the support plate, as seen in <FIG>, <FIG>, <FIG>.

Referring to <FIG>, which shows an ice bin according to claim <NUM>, the shell <NUM> comprises a sub-frame that supports perimeter wall panels of the shell. Each of the left and right sides of the shell <NUM> includes an upright frame member <NUM> of the sub-frame. In <FIG>, a portion of the right panel wall is shown transparent to reveal the upright frame member <NUM>, which would otherwise be hidden behind the panel wall. In the illustrated embodiment, the upright frame member <NUM> is located closer to the front of the bin <NUM> than the back of the bin. The upright frame member <NUM> is formed from ferromagnetic material such as galvanized steel so that the scoop <NUM> can be supported on an exterior of the bin <NUM> by a force of magnetic attraction between the upright frame member and the magnetic elements <NUM> of the scoop. In one or more embodiments, the ferromagnetic upright frame member <NUM> is immediately adjacent the panel wall of the shell and is separated from the liner <NUM> by insulation material. By contrast, each of the support plates <NUM> is located immediately adjacent to the liner <NUM> and is spaced apart from the panel wall by insulation material. Hence, the support plates <NUM> enable the scoop <NUM> to be magnetically supported inside the bin <NUM>, whereas the upright frame member <NUM> enables the scoop to be magnetically supported outside the bin.

An exemplary method of using the ice bin <NUM> according to claim <NUM> and scoop <NUM> will now be briefly described below. An ice machine (not shown) is supported above the upper portion of the ice bin <NUM> for forming ice and depositing ice into the bin. When the ice is formed, the ice machine drops the ice through the ice drop opening <NUM> defined by the upper portion <NUM> and into the interior ice bin <NUM> defined by a liner <NUM>. The liner <NUM> houses the ice within the interior until a future user desires its use. While in the liner <NUM>, the ice is hindered from melting due to an insulation layer (not shown) disposed between the outer shell <NUM> and the liner. When the user decides to use the ice in the bin <NUM>, the user opens the door <NUM>. In the initial position, the scoop <NUM> is supported in a position on the liner <NUM> overlying the support plate <NUM>. In this initial position overlying the support plate <NUM>, the scoop <NUM> is also out of the path of ice being dropped through the ice drop opening <NUM>. The scoop <NUM> is supported onto the liner <NUM> through the force of magnetic attraction between magnetic elements <NUM> in the scoop and the ferromagnetic material of the support plate. The user grabs the handle <NUM> of the scoop <NUM>, and by applying force, overcomes the magnetic force between the magnetic elements <NUM> of the scoop <NUM> and the support plate <NUM> and frees the scoop from its supported position on the liner <NUM>. The user then scoops ice out of the liner <NUM> using the scoop <NUM>. The ice collects in the bowl <NUM> of the scoop <NUM> to facilitate transfer of the ice to a desired location. Once the user has dispensed the ice outside of the ice bin <NUM>, the user places the scoop <NUM> in the area overlying the support plate <NUM> on the interior of the liner <NUM>. In one or more embodiments, the liner <NUM> has a marking indicating the location of the support plate <NUM> so that the user can visualize where to place the scoop. The magnetic force between the magnetic elements <NUM> and the support plate <NUM> once again supports the scoop <NUM> on the interior of the liner <NUM>. Alternatively, the user may utilize the scoop <NUM> in substantially the same way, only with the scoop being supported on the exterior surface of the outer shell <NUM> in the area overlying the upright support member <NUM>.

An exemplary method according to claim <NUM> of manufacturing an ice bin <NUM> according to claim <NUM> as described above will now be briefly described below. The method according to claim <NUM> includes steps of forming a liner <NUM>, forming the outer shell <NUM>, temporarily supporting the support plates <NUM> on the liner via double-sided tape, and fitting the liner in the shell and support plates in the space between the liner and the shell. The particular order of these steps is not critical. So in one or more embodiments, the liner <NUM> can be formed, then the support plates <NUM> can be temporarily secured to the liner, and then the shell can be assembled around the liner. In another embodiment, the liner <NUM> and outer shell <NUM> are each formed in suitable manufacturing processes, the support plates <NUM> are then temporarily secured to the liner, and then the assembly of the liner and the support plates is inserted into the shell. In yet another embodiment, the liner <NUM> and outer shell <NUM> are each formed in suitable manufacturing processes, the liner is then slipped into the outer shell, and then the plates are temporarily secured to the liner in the space between the liner and shell. Any suitable manufacturing processes can be used to form the liner <NUM> and the shell <NUM>. In an exemplary embodiment, the liner <NUM> is formed in a blow molding process, from blow-molded plastic. The shell <NUM> may suitably be formed by assembling a sub-frame and then securing outer shell wall panels to the sub-frame vial suitable fasteners or mechanical tabs or hooks. As mentioned above, in an exemplary embodiment, the support plate <NUM> is temporarily fitted onto the liner <NUM> using an adhesive (e.g., a double-sided tape). After the support plate <NUM> is temporarily secured and the liner <NUM> is in the outer shell <NUM>, an insulation layer is foamed in the space between the outer shell and the liner in order to insulate the bin <NUM> and permanently secure the support plate in position. Curable insulation material is imparted into the space so that it substantially fills the space and conforms to the support plates <NUM>. The insulation material is then cured to provide a firm hold of the support plate <NUM> in the desired position.

An exemplary method of manufacturing a scoop <NUM> as described above will now be briefly described below. The method includes forming a scoop <NUM> comprising a magnetic element receiving enclosure <NUM> having an open end, placing a magnetic element <NUM> into the magnetic element receiving enclosure through the open end, and joining a cap <NUM> to the scoop <NUM> over the open end of the magnetic element receiving enclosure such that the cap retains the magnetic element in the enclosure. In one embodiment, the joining of the cap <NUM> comprises ultrasonic welding the cap to the scoop <NUM>. The scoop <NUM> may be formed by molding the scoop, and the scoop is preferably comprised of plastic.

The inventors believe that the above-described ice bin <NUM> and scoop <NUM> provide several advantages. As compared with prior art bins in which an ice scoop was placed directly atop the ice, the bin <NUM> and scoop <NUM> of the present disclosure are believed to provide a much more sanitary way of holding the scoop at a convenient, ready-to-use position. Whereas placing a scoop directly atop ice runs a risk of transferring germs and other pathogens from a user's hands, to the scoop, and further to the ice in the bin, the illustrated ice bin <NUM> and scoop <NUM> enable the user to quickly and easily position the scoop at a ready-to-use position without direct contact with the ice. Moreover, as compared with prior art ice bins that include integrated brackets for supporting a scoop out of the way of the ice, the illustrated bin <NUM> and scoop <NUM> are believed to provide a much more convenient, user-friendly mechanism for supporting the scoop. The inventors have recognized that scoop-holding brackets inside an ice bin are often difficult to use (particularly for uses with physical limitations due to injury or disability) because they only allow the user to support the scoop at a particular location and orientation. By contrast, the illustrated support plates <NUM> provide a wide range of possibilities for where and how a user can support the scoop <NUM> on the side wall of the bin, out of contact with the ice and out of the way of ice maker operation.

Referring to <FIG>, in another embodiment the ice bin is integrated with the ice maker <NUM>, as is the case with the residential-style ice maker, generally indicated at <NUM>. The residential ice maker includes a bin body <NUM> comprising a front door assembly <NUM> configured to releasably support the magnetic scoop <NUM> discussed above. The illustrated door assembly <NUM> is configured to mount on the bin body <NUM> with hinges to swing open and closed. The door assembly <NUM> comprises a shell <NUM> and a liner <NUM> defining a space therebetween configured to receive insulation. Similar to the bin body <NUM> discussed above, the illustrated door assembly comprises a support plate <NUM> secured to the liner <NUM>. In the illustrated embodiment the support plate <NUM> is configured to align with an opening through which the user withdraws ice from the ice maker appliances when the door is open. In an exemplary embodiment, the support plate <NUM> is temporarily secured to the liner <NUM> with tape and then foamed into place for a permanent installation (similar to the support plate <NUM> described above). As can be seen, the support plate <NUM> allows the magnetic scoop <NUM> to support itself on the door assembly <NUM> at a position that still allows the door to open and close. During use, the user can open the door <NUM>, separate the scoop <NUM> from the door, withdraw ice from the residential ice bin <NUM>, return the scoop to the door such that scoop is supported on the door by a force of magnetic attraction between the scoop and the door, and finally shut the door.

Claim 1:
An ice bin (<NUM>) comprising:
a bin body, the bin body (<NUM>) comprising a lower portion (<NUM>), an upper portion (<NUM>), and a perimeter wall (<NUM>) extending heightwise from the lower portion to the upper portion, the upper portion of the bin body defining an ice drop area (<NUM>) configured so that ice dropped from an ice maker supported above the ice bin is passable through the ice drop area into the interior, the bin body further comprising an ice retrieval area (<NUM>) spaced apart from the ice drop area for providing access to the interior of the ice bin, characterized in that the perimeter wall comprises a support plate (<NUM>) configured to support an ice scoop (<NUM>) on the perimeter wall in the interior of the ice bin by a force of magnetic attraction between the ice scoop and the support plate, wherein the ice bin (<NUM>) further comprises an upright frame member (<NUM>) formed from ferromagnetic material so that the ice scoop can be supported on an exterior of the ice bin by force of magnetic attraction between the upright frame member and the ice scoop