Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This patent application claims the benefit of U.S. Provisional Patent Application No. 60/648,893, filed Feb. 1, 2005. The entire disclosure of which is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates generally to ice dispensers with the capability to dispense either crushed or cubed ice.  
       SUMMARY OF THE INVENTION  
       [0003]     The ice dispenser of the present invention allows for the selection of either cubed ice or crushed ice. More specifically, the present invention relates to an improved self-contained, modular design. The present invention may be adapted for use in both consumer and commercial markets and has the potential for, but is not limited to, applications in equipment such as stand-alone ice crushers, refrigerators, and soft drink dispensers.  
         [0004]     Accordingly, the present invention comprises of an ice feeding mechanism which transports ice through a duct to an ice crusher assembly. The ice crusher is driven by a separate motor. The invention also includes a bypass gate which allows ice to bypass the crusher assembly when cubed ice is selected for dispensing. Both cubed and crushed ice are routed and dispensed through a single ice chute.  
         [0005]     The present ice dispenser allows for the selection of the type of ice to be dispensed: cubed ice or crushed ice. The ice type selection type usually occurs prior to dispensing, but the selection may also be made during the dispensing of ice. The means for the ice type selection may be made by, but is not limited to, a device such as a switch. If cubed ice is selected, the bypass gate is opened allowing ice to bypass the ice crusher assembly. If crushed ice is selected, the bypass gate is closed, and ice is delivered to the ice crusher. Opening and closing of the bypass gate is accomplished by means of a motor-driven worm drive, but may also be accomplished by means of an electric solenoid, pneumatic or hydraulic cylinder, or other actuating device.  
         [0006]     Ice is supplied to the ice dispenser assembly from an ice bin, ice chest, or other ice reservoir and enters the auger duct. When the ice dispenser is activated, by means of a switch or other input device, the ice is transported through the length of the duct by a motor-driven auger. If cubed ice is the current selection, the ice then passes through the bypass gate, and the cubed ice exits the dispenser through the ice chute. If crushed ice is the current selection, the ice is delivered to the ice crusher, is crushed, and crushed ice exits the dispenser through the ice chute.  
         [0007]     Brief Explanation of Unique Components  
         [0008]     1. Two Motor System  
         [0009]     2. Modular Design  
         [0010]     3. Bypass gate system  
         [0011]     4. Paddle blades  
         [0012]     5. Ice crusher assembly  
         [0013]     6. Ice crusher drive system  
         [0014]     7. Ice chute  
         [0015]     8. Electronic Controls  
         [0016]     1. Two-Motor System 
        The invention utilizes a two-motor system for the auger and ice crusher; the auger and ice crusher each have a dedicated motor. This allows for completely independent control of the auger and ice crusher and increases the flexibility of the invention over previous crushed ice dispensers.     Because the auger and crusher each have an independently controlled motor, the speed of the auger can be adjusted without affecting the speed of the crusher and vise-versa. This gives the invention the capability to crush and dispense different types of ice produced by the multitude of ice makers available. The rate at which the auger feeds ice to the ice crusher and the speed of the ice crusher can be each adjusted to optimally crush and dispense ice of various geometries and densities.     Another advantage of independent motors for the crusher and the auger is that when cubed ice is dispensed, the crusher motor can be deactivated. This will render the crusher idle, allowing no further ice crushing to occur, and only cubed ice will be dispensed.     Additionally, the two-motor system allows the crushed ice dispenser to perform ice jam correction operations that would be difficult to accomplish with a single motor system, such as variable auger and crusher rotation speeds and independently reversible auger and crusher rotation directions.        
 
         [0021]     2. Modular Design 
        The invention is designed so that all of the crushed ice dispenser&#39;s mechanical components are integrated into a single modular assembly. This allows the crushed ice dispenser design to easily be configured for use as either a stand-alone ice crusher or for integration into a multifunctional appliance, such as a refrigerator/freezer or beverage dispenser. The modular design of the crushed ice dispenser is an advantage for the manufacture of such appliances since it can be procured as a single subassembly.     The modular design also reduces the complexity of servicing the crushed ice dispenser because it can easily be removed entirely from the appliance for service or replacement.        
 
         [0024]     3. Bypass Gate System 
        The crushed ice dispenser features a bypass gate system to bypass the ice crusher when cubed ice is selected. The gate is driven by a motor and worm drive system, but may also be driven by a solenoid, pneumatic or hydraulic cylinder, or some other type of actuation device. When crushed ice is selected, the bypass gate is closed, and ice is transported to the ice crusher. When cubed ice is selected, the bypass gate is opened, and ice bypasses the ice crusher to fall directly into the ice chute. Unlike existing ice crushers, the bypass gate is located external of the ice crusher. The external bypass gate reduces the delay time when changing selections between cubed and crushed ice, and reduces the complexity of the invention.        
 
         [0026]     4. Paddle Blades 
        The crushed ice dispenser utilizes an auger with a 2 bladed paddle at its end. The paddle blades exert a positive force onto the ice, pushing it into the ice crusher, resulting in a faster and more consistent ice dispense than equipment available today. The blades are composed of a flexible material, such as rubber, to aid in the reduction of ice jams and by touching the walls of the chute prevent sticking of ice. If an ice jam does occur within the crusher, the soft paddle blade material will fold over itself, and the auger will continue to turn.        
 
         [0028]     5. Ice Crusher Assembly 
        The crushed ice dispenser utilizes a compact ice crusher assembly. The ice crusher blades rotate at a high speed. In addition to crushing ice, the blades also increase the velocity of the ice as it exits the crusher assembly. This results in a high rate of crushed ice dispense.        
 
         [0030]     6. Ice Crusher Drive System 
        The invention&#39;s ice crusher motor drives the ice crusher through a roller chain and sprocket system or timing belt and pulley system This allows greater flexibility in the mounting of the ice crusher motor within the crushed ice dispenser and aids in keeping the assembly compact in size.        
 
         [0032]     7. Ice Chute 
        The crushed ice dispenser ice chute has two inlet paths: one for cubed ice and one for crushed ice. The two paths converge into one outlet at which both cubed and crushed ice is dispensed.        
 
         [0034]     8. Electronic Controls 
        All of the operations of the crushed ice dispenser are managed by an electronic control board. The control board handles inputs such as cubed or crushed ice selection, and the position of the bypass gate, and controls the speed of the auger, crusher, and bypass gate motors. The electronic controls also monitors the current draw of each motor to determine if an ice jam has occurred If an ice jam does occurs, the control is programmed to rotate the auger and/or crusher blades in a certain manner to free the ice jam.        
 
         [0036]     Advantages and Objects of the invention over the prior products, patents, and publications: 
        Can be adapted for use in many applications, both commercial and consumer     Ability to crush ice of various geometry and densities     Faster dispense of crushed ice     Fewer ice jams and the ability to free ice jams if they occur     Modular design       
 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0042]     The invention is pointed out with particularity in the claims. The above and further features and benefits of the invention are better understood by reference to the following detailed description taken together with the accompanying drawings in which:  
         [0043]      FIG. 1  is a first perspective view of the ice dispenser;  
         [0044]      FIG. 2  is second perspective view of the ice dispenser assembly taken from the side opposite the side of the view of  FIG. 1 ;  
         [0045]      FIG. 3  is a plan view of the ice dispenser;  
         [0046]      FIG. 4  is an exploded view of the ice dispenser;  
         [0047]      FIG. 5  is a perspective view of the ice crusher integral with the ice dispenser;  
         [0048]      FIG. 6  is an exploded view of the ice crusher;  
         [0049]      FIG. 7  is a cross sectional view of the ice crusher and discharge chute taken along line  7 - 7  of  FIG. 3 ;  
         [0050]      FIG. 8  is a side view of the ice dispenser illustrating the connection between the ice crusher and the motor that actuates the ice crusher; and  
         [0051]      FIG. 9  is a block diagram of the control circuit of the ice dispenser of the beverage dispenser of this invention. 
     
    
     CRUSHED ICE DISPENSER ASSY  
       [0052]     An example configuration of the crushed ice dispenser is shown in the drawings. The primary external components are shown; the auger motor is coupled to the auger; the auger resides within the auger duct; the bypass gate is positioned in front of the crusher assy and slides along the auger duct. In this example, a motor rotates a worm drive shaft to open and close the bypass gate. The crusher motor is located above the crusher assy; and in this example, a timing belt system transmits power from the crusher motor to the crusher assy. The ice chute is assembled at the end of the auger duct, below the ice crusher assy.  
         [0000]     Crushed Ice Dispenser Assy, Exploded  
         [0053]     The exploded assembly of the crushed ice dispenser is shown illustrating all the major components. The auger is assembled within the auger duct. At the end of the auger is a pair of paddle blades which push the cubed ice into the ice crusher. The paddle blades are constructed of a flexible material which allows the blades to fold and the blade ends touch the wall of the duct. This minimizes the occurrence of ice jams.  
         [0000]     Auger and Bypass Gate  
         [0054]     The drawing figures illustrate how the auger transports ice through the crushed ice dispenser in both the cubed ice and crushed ice selection modes. Ice enters the auger duct and is pushed down the length of the auger duct by the auger. When the dispenser is in cubed ice mode, the bypass gate is open, and the ice exits the auger duct through the bypass gate and falls into the ice chute. When the dispenser is in crushed ice mode, the bypass gate is closed, the cubed ice is pushed by the auger past the bypass gate, and the paddle blades push the ice into the ice crusher.  
         [0000]     Bypass Gate System  
         [0055]     The functionality of the bypass gate is shown in both the cubed ice and crushed ice selection modes. In the crushed ice mode, the bypass gate is closed, and the auger transports the cubed ice to the crusher. In the cubed ice mode, the bypass gate is open, and the cubed ice falls through the opening and into the ice chute. The bypass gate slides along the auger duct. In this example, the bypass gate is driven by a motor and worm dive.  
         [0000]     Bypass Gate Assy  
         [0056]     Shown in the drawings is one possible configuration of the bypass gate assembly with a worm drive system. The bypass gate motor turns a worm drive. Assembled to the bypass gate are bearings that run along the helix of the worm drive. As the motor turns, the bypass gate is moved along the length of the auger duct. The bypass gate is curved to conform to the outer diameter of the auger duct.  
         [0000]     Ice Crusher System  
         [0057]     The drawings illustrate how the crushed ice dispenser dispenses crushed ice. In the crushed ice selection mode, the bypass gate is closed, and cubed ice is transported by the auger to the paddle blades. The paddle blades push the ice into the crusher assembly where the cubed ice is crushed by the rotating crusher blades. The crusher blades are attached to the rotating crusher shaft which is driven by the crusher motor. In this example, the crusher motor transmits power to the crusher through a timing belt system. The crusher blades also add velocity to the ice as it exits the crusher and enters the ice chute, resulting in a greater crushed ice dispense rate than existing crushed ice dispensers.  
         [0000]     Ice Crusher Assy  
         [0058]     The ice crusher assembly is includes a set of stationary blades integrated into the base of the crusher and a set or rotating blades assembled to a rotating shaft. As ice enters the crusher assembly, the ice is crushed between the stationary and rotating blades and then pushed out of the crushing assembly by the motion of the rotating blades into the ice chute. The blades are spaced along the shaft by spacers, and the shaft is secured to the base with retainers. In this example, the shaft rotates on bushings, but bearings may also be used in higher demand applications. The geometry of the blades is such that the blades can crush ice in either rotational direction. This gives the ice dispenser greater effectiveness in eliminating ice jams.  
         [0000]     Ice Chute  
         [0059]     These drawings illustrate the ice chute design used in the crushed ice dispenser. The ice chute is configured to have two inlets: one inlet for cubed ice and one inlet for crushed ice; and one outlet for both cubed and crushed ice. Cubed ice falls into the cubed ice inlet when the crushed ice dispenser is in cubed ice selection mode and the bypass gate is open. Crushed ice is pushed into the crushed ice inlet by the crusher when the crushed ice dispenser is in crushed ice mode and the bypass gate is closed. Both cubed ice and crushed ice inlets converge, and both types of ice exit the ice chute through the same outlet.  
       DETAILED DESCRIPTION  
       [0060]     Refering now to the drawings,  FIGS. 1 and 2 , chute  26  and crusher  28  are part of an ice dispenser  40 . The ice dispenser  40  also includes a tube-shaped auger duct  42 . A plate shaped mounting flange  44  is molded with or otherwise integrally attached to the circumferential surface of the auger duct  42  at one end of the duct. The auger duct  42  is further formed to have an inlet opening  46  (shown in phantom in  FIG. 4 ) that extends through the mounting flange  44  into the center void space of auger duct  42 .  
         [0061]     The ice dispenser  40  is positioned in the dispenser  20  so that the mounting flange  44  is disposed against the outer front wall of an ice bin  24  (not shown). More particularly, the ice dispenser  40  is positioned so that auger duct inlet opening  46  is in registration with an ice discharge opening formed in the front wall of the ice bin  24  (ice bin opening not illustrated). Fasteners (not illustrated) extend through openings  50  formed in the mounting flange  44  to secure the ice dispenser  40  to the rest of the beverage dispenser  20 . In some versions of the invention, mounting plate flange openings  50  are keyhole-shaped openings. Pins with relatively large heads are permanently affixed to and extend out from the wall of the ice bin  24  to which the ice dispenser  40  is attached. In this version of the invention, ice dispenser  40  is removably attached to the ice bin  24  by positioning the mounting flange  44  so that the ice bin pins seat and lock in the flange openings  50 . This feature makes it easy to remove and replace ice dispenser  40  for maintenance.  
         [0062]     The end of auger duct  42  adjacent mounting flange  44  is closed by a disc-shaped end cap  54  (shown in  FIG. 5 ). In the depicted version of the invention, an end cap  55  formed integrally with the auger duct  42  closes the opposed end of the duct. The auger duct  42  is further formed to have two laterally directed, longitudinally aligned and longitudinally spaced apart openings adjacent the end opposite mounting flange  44 . A first opening, primary opening  56 , is located immediately rearward the end of the duct. In the depicted version of the invention, the auger duct  42  is formed with a rectangular-shaped flange  58  that surrounds primary opening  56  and extends laterally outward from the main circular body of the duct. The second opening, bypass opening  60 , is located adjacent flange  58 . The auger duct  42  is formed so that, relative to primary opening  56 , bypass opening  60  is proximal to the duct inlet opening  46 . The primary and bypass openings  56  and  60 , respectively, are longitudinally aligned with each other.  
         [0063]     Auger duct  42  is further formed to have four rectangularly-shaped protuberances  61 . Two of the protuberances  61  are positioned on the outer surface of the top wall of flange  58 . The remaining two protuberances  61  (one illustrated in  FIG. 8 ) are integral with and project outwardly from outer surface of the bottom wall of flange  58 .  
         [0064]     An auger  62  is disposed inside the auger duct  42 . The auger  62  is disposed over an elongated shaft  64  that extends axially through the auger duct  42 . One end of shaft  64  is mounted in and extends a short distance beyond a through hole  68  formed in end cap  54 . The opposed end of shaft  64  is rotatably seated in a center-located boss  71  formed in end cap  55 . Not identified is the opening in boss  71  in which the shaft  64  is seated. In some versions of the invention, sleeves formed of low friction material are positioned between the ends of shaft  64  and the static parts of the auger duct to function as bearings.  
         [0065]     Auger  62  extends longitudinally through the auger duct  42  from duct inlet opening  46  to the bypass opening  60 . The auger  62  is mounted to shaft  64  to rotate with the shaft. A paddle blade  66  is mounted to the end of the shaft  64  that extends through the space internal to the auger duct  42  subtended by primary opening  56 . Paddle blade  66 , like auger  62 , is fitted to shaft  64  to rotate with the shaft. In the illustrated version of the invention, a cylindrical spacer  69  disposed on shaft  64  longitudinally separates the paddle blade  66  from the auger  62 . Auger  62  is shaped so that, upon rotation, the auger pushes the ice cubes from duct inlet opening  46  towards primary opening  56  and bypass opening  60 . Paddle blade  66  is shaped to, upon rotation, push ice cubes through the primary opening  56 . Paddle blade  66  is preferably made of a flexible material, such as rubber, which allows the blade to fold so as to minimize the occurrence of ice jams.  
         [0066]     Shaft  64  and, by extension, auger  62  and paddle blade  66 , are rotated by an auger motor  70 . The auger motor  70  is located adjacent end cap  54 . Not shown is a bracket that holds auger motor  70  fast to either auger duct  42  or mounting flange  44 . The auger motor  70  has an output shaft  72  directed toward end cap  54 . A cylindrical coupling sleeve  74  couples the auger shaft  64  to the motor shaft  72  so the two shafts move in unison. As seen in  FIG. 5 , fasteners  76  that extend into laterally directed openings in sleeve  74  (openings not identified) hold the two shafts  64  and  72  to the sleeve.  
         [0067]     A bypass gate  80 , also part of ice dispenser  40 , selectively opens and closes the auger duct bypass opening  60 . The bypass gate  80 , best seen in  FIGS. 3 and 5 , has a curved main body  81  that surrounds an arcuate section of the auger duct  42 . Bypass gate  80  is mounted to a threaded drive shaft  82 . The drive shaft  82  is rotated by and suspended from a bypass gate motor  84 . In the depicted version of the invention, the bypass gate motor  84  is laterally spaced from the auger duct  42  and located in front of the mounting flange  44 . Not shown is a bracket that holds the bypass gate motor  84  to the mounting flange  44 .  
         [0068]     In addition to the curved main body  81 , bypass gate  80  has three parallel aligned and spaced apart tabs  86  that extend away from the plate main body (see  FIG. 3 ). A sleeve  88  with a through bore that has interior threading (through bore not illustrated) is held away from the gate main body  81  by tabs  86 . Sleeve  88  is the bypass gate component that threadedly engages drive shaft  82 . The rotation of the drive shaft  82  causes the bypass gate  80  to move longitudinally along the length of the auger duct  42 . The bypass gate  80  is positioned relative to the auger duct  42  so that when the gate main body  81  is spaced distally from the bypass gate motor  84 , the gate main body covers the duct bypass opening  60 . When the bypass gate  80  retracts towards motor  84 , the gate main body  81  moves away from the bypass opening  60 . Alternately, bypass gate  80  may be driven by an electric solenoid, a hydraulic or pneumatic cylinder, or some other type of known actuation device.  
         [0069]      FIGS. 6 and 7  illustrate the ice crusher  28  of the beverage dispenser  20  of this invention. Ice crusher  28  includes a base  90  formed of a single piece of rigid material. Base  90  has a generally square frame  92 . A head  94  projects forward, towards chute  26 , from the frame  92 .  
         [0070]     Head  94  is formed to have two rows of parallel stationary blades  96 . The two rows of stationary blades  96  are spaced apart from each other to define an elongated gap  98  in the head  94  that extends along the longitudinal axis of the head. In each row, the individual stationary blades  96  are spaced apart from each other to define a longitudinally extending slot  102  between each pair of adjacent blades. Each stationary blade  96  is further positioned to be longitudinally aligned with a blade in the opposed row. Thus, each slot  102  is aligned with a complementary slot  102  in the opposed row. Base  90  is further formed so that the stationary blades  96  have tapered cross-sectional profiles. Specifically, the rearward directed face of each stationary blade  96  has a relatively narrow cross sectional width; the forward directed face of the blade has wider cross sectional width. Slots  102  thus have tapered profiles opposite in direction to those of the stationary blades  96 .  
         [0071]     A moving blade assembly  104  is rotatably mounted to ice crusher base  90 . Blade assembly  104  includes an elongated shaft  106  that seats in base gap  98 . Shaft  106  has a main body  108  with a square cross-sectional profile. At one end of the main body  108 , shaft  106  has a cylindrical head  110 . Head  110  has a diameter larger than the cross sectional area subtended by the shaft main body  108 . The opposed end of the shaft  106  has a cylindrical stem  112 . Stem  112  has a diameter smaller than the cross sectional area subtended by the shaft main body  108 .  
         [0072]     A number of blades  114  are mounted to the shaft  106  to rotate with the shaft. Each blade  114  has a circular base  116 . The blade base  116  is formed to have a center located opening  118 . The blade base openings  118  are square in shape and are dimensioned to facilitate the close slip fitting of the blade bases  116  over the shaft main body  108 . A head  120  is integrally formed with and extends radially outwardly from each blade base  116 . The opposed surfaces that define the sides of the head  120  are inwardly curved. The edge surface that defines the top of blade head  120  curves outwardly.  
         [0073]     Blade assembly  104  has a number of blades  114  equal to the number of pairs of opposed aligned slots  102  defined by the ice crusher base  90 . Tube-shaped spacers  122  longitudinally separate the blades  114  along the length of the shaft main body  108 . An additional spacer  122  is located over the shaft main body  108  between the shaft head  110  and the adjacent blade  114 . A spacer  122  is located between the shaft stem  112  and the adjacent blade  114 . When the blade assembly  104  is assembled, the individual blades  114  are oriented relative to each other so that the radial positions of the blade heads  120  are angularly spaced apart. The geometry of the blades is such that ice is crushed in either rotational direction, which provides greater effectiveness in eliminating ice jams.  
         [0074]     Shaft retainers  124  and  126  and bushings  128  and  130  rotatably hold blade assembly  104  to the crusher base  90 . At one end of the base  90 , frame  92  has an inner section formed with a concave surface (not identified) that defines a circular notch  132  in which shaft head  110  is seated. Shaft retainer  124  seats over the shaft head  110  and holds shaft head  110  in position. While the shaft retainer  124  is generally in the form of a bar, the retainer has a concave surface  134  to facilitate the close seating of the retainer over shaft head  110 . Fasteners  135  extend through holes formed in the shaft retainer  124  and frame  92  to hold the shaft retainer to the ice crusher frame  90  (holes not identified).  
         [0075]     Bushing  128 , formed of a solid low friction material, is disposed around shaft head  10 . Bushing  128  provides a low friction interface between the rotating shaft  106  and the static ice crusher base  90  and retainer  124 .  
         [0076]     The side of the base frame  92  opposite the side that defines notch  132  is formed with an inwardly curved inner surface  136 . Surface  136  is curved to define a notch (not identified) identical in shape to notch  132 . The side of the base frame in which curved inner surface  136  is formed with a slot  138 . Slot  138  opens into the notch defined by surface  136 . When ice crusher  28  of this invention is assembled, the shaft stem  112  extends outwardly across frame inner surface  136  and out through slot  138 .  
         [0077]     Shaft retainer  126  seats over the shaft stem  112 . The shaft retainer  126  has a shape similar to, if not identical to, that of shaft retainer  124 . Bushing  130 , formed from the same material as bushing  128 , is disposed around the portion of shaft stem  112  that extends between the frame inner surface  136  and the shaft retainer  126  and through slot  138 . Fasteners  135  hold the shaft retainer  126  to the ice crusher base  90 .  
         [0078]     The base frame  92  is further formed so that the surfaces that define the spaces in which the shaft  108 , shaft retainers  124  and  126  and bearings  128  and  130  seat are recessed relative to the rear edge of the frame. Thus, blade assembly  104 , with the exception of the blade heads  120 , is disposed within the space enclosed by the base frame  92 .  
         [0079]     Ice crusher base  90  seats over the rectangular flange  58  of auger duct  42 . To facilitate the mounting of the ice crusher  28  to the rest of the ice dispenser  40 , the base frame  92  is formed on the top and bottom surfaces to have raised ribs  140  and  142 , respectively. Each rib  140  and  142  extends the width of the frame surface with which the rib is integral. When the ice crusher  28  is seated against duct flange  58 , ribs  140  and  142  abut the protuberances  61  integral with the flange.  
         [0080]     A crusher motor  144 , best seen in  FIGS. 4 and 5 , rotates the moving blade assembly  104 . The crusher motor  144  is located above the auger duct  42  adjacent the end of the duct to which the ice crusher  28  is mounted. Not illustrated is the bracket that holds the crusher motor  144  to the auger duct  42 . Crusher motor  144  has a motor shaft  146  that extends parallel to shaft  64  internal to the auger duct  42 . Motor shaft  146  extends a short distance beyond the adjacent closed end  55  of auger duct  42 . Crusher motor  144  is controlled and operates independently of auger motor  70 .  
         [0081]     A pulley  148  is mounted for rotation to the free end of motor shaft  146 . A complementary pulley  150  is mounted to the end of the blade assembly shaft stem  112  that extends beyond the crusher base  90 . A drive belt  152  disposed around the pulleys  148  and  150  couples the pulleys for simultaneous rotation. Alternately, a roller chain and sprocket arrangement may be utilized instead of a drive belt and pulley arrangement to drive the ice crusher.  
         [0082]     The ice chute  26 , now described by reference to  FIGS. 3, 4 ,  5 ,  8  and  9 , is formed from bottom and top moldings  156  and  158 , respectively. Lower molding  156  is shaped to have an open, rectangularly-shaped frame  160 . Specifically, lower molding  156  is shaped so that frame  160  closely slip fits around the section of the ice crusher head  94  that extends forward of the ice crusher base frame  92 . Extending forward and from frame  160 , lower molding  156  has a first slide  162  that extends diagonally downwardly. The first slide  162  has a cross-sectional shape that transitions from three-sided (bottom surface and two opposed side surfaces) adjacent frame  160  to semi-circular adjacent the open end of the chute  26 .  
         [0083]     Bottom molding  156  is further shaped to have second slide  164  parallel to the first slide  162 . The bottom molding  156  is formed so that the second slide  164  starts at a position rearward of frame  160 . A plate  166  closes the most rearward end of the second slide, the end that extends beyond frame  160 . This most-rearward section of the second slide  164  is formed as a three-sided structure; a base wall and two parallel, spaced apart side walls (individual wall sections not identified.) For reasons that are apparent below, side walls of the second slide  164  that extend rearward of frame  160  are formed to have concaved edges  168  which define a radius slightly greater than that defined by the bypass gate main body  81 .  
         [0084]     Chute bottom molding  156  is further formed so that, forward of frame  160 , a single internal flange member  170  forms opposed sides of the first and second slides  162  and  164 , respectively. Flange  170  terminates a short distance forward of frame  160  so that the flow path defined by the second slide  164  merges into the flow path defined by the first slide  162 .  
         [0085]     The chute bottom molding  156  is further formed to have a head piece  172 . Head piece  172  extends forward from the outer wall of the molding  156  that defines the outer wall of the second slide  164 . At the forward end of the bottom molding  156 , the head piece  172  curves around and extends over the space where the flow path of the second slide  164  merges into the flow path of the first slide  162 . Bottom molding  156  is further shaped so that a diverter panel  174  extends rearwardly from the free end of the head piece  172 . Diverter panel  174  is disposed above the flow path defined by the first slide  162 .  
         [0086]     Top molding  158  is disposed over bottom molding  156 . The top molding  158  is formed to have a first side wall  180  that projects upwardly from the outer wall of first slide  162 . The top molding  158  has a second side wall  182  that extends upwardly from the outer wall of the second slide  164 . A top wall  184 , also part of top molding  158 , extends between side walls  180  and  182 . The ice chute  26  is further formed so that when top molding  158  is fitted over bottom molding  156 , the top wall  184  is disposed over the top of the leading edge of frame  160  and over diverter panel  174 .  
         [0087]     Extending rearward from the top wall  184 , the top molding  158  has a three-sided hood  186 . Hood  186  extends rearward from the section of top molding  158  that extends laterally from the ice crusher base  90 . A top wall  188  of hood  186  is flush with the molding top wall  184 . A first side wall  190  of hood  186  is positioned to be adjacent and extend rearward of bottom molding frame  160 . A second side wall  192  of hood  186  extends rearwardly from side wall  182 .  
         [0088]     The top molding  158  is also shaped to define a nose  196  that extends forward from the top wall  188 . Nose  196  has a semicircular cross section profile that is downwardly directed. When moldings  156  and  158  are mated together, the opposed edges of nose  196  seat against the opposed edges of the forward end of the first slide  162 . The forward end of the first slide  162  and nose  196  collectively form the opening  198  of chute  26  through which ice is discharged.  
         [0089]     In the illustrated version of the invention, bottom and top moldings  156  and  158 , respectively, are snap fitted together. Integrally formed with the bottom molding  156  are outwardly directed fingers  202 . The top molding side walls  180  and  182  are each formed with a U-shaped downwardly directed bracket  204 . Collectively, the fingers  202  and brackets  204  are positioned so that when the top molding  158  is positioned over the bottom molding  156 , the fingers snap against surfaces integral with the brackets to hold the moldings together.  
         [0090]     The ice chute  26  is further formed to have four tabs  206  integral with bottom molding frame  160 . Two of the tabs  206  extend from the top of the frame  160  and are positioned to be aligned with the upper two auger duct protuberances  61 . Two of the tabs  206  extend from the bottom of frame  160  (one tab seen) and are positioned to be aligned with the lower two auger duct protuberances.  
         [0091]     As part of the assembly of ice dispenser  40 , the ice crusher  28  is fitted against auger duct flange  58  and the ice chute  26  is fitted over the ice crusher so that crusher head  94  seats in the duct frame  160 . Pairs of fasteners  208  and  210  extend through concentric openings formed in the flange protuberances  61 , ice crusher ribs  140  and  142  and chute tabs  206  (openings not identified). Each pair of fasteners  208  and  210  interlock to hold the ice chute  26  and ice crusher  28  to the auger duct  42 .  
         [0092]     When the ice dispenser  40  is so assembled, the rear end of the bottom molding second slide  164  is disposed under the auger duct bypass opening  60 . Top molding hood  186  extends rearwardly, towards the auger duct bypass opening  60 . Thus, hood  186  extends rearwardly beyond the ice crusher  28 . The rear end of the second slide  164  is disposed below bypass opening  60 . However, the ice chute  26  is shaped so that both the second slide  164  and hood  186  are spaced from the auger duct  42 . Specifically, the second slide  164  and hood  186  are positioned to define a space between the ice chute  26  and the auger duct  42  in which the bypass gate main body  81  can freely move.  
         [0093]     Ice dispenser  40  also includes a lever arm  214  ( FIG. 1 ) located immediately below ice chute  26 . Lever arm  214  is pivotally mounted to a static portion of the beverage dispenser  20 . The lever arm  214  is positioned relative to the ice chute  26  so that, when a container is placed under the chute opening  198 , the lever arm is pivoted. A sensor  218 , seen in  FIG. 10 , monitors the pivotal displacement of the lever arm  214 . The signal generated by sensor  218  is supplied to a control unit  220  that regulates the operation of the ice dispenser  40 . Also connected to the control unit  220  is a control switch  222 . Switch  222  is actuated to set the dispenser  40  to discharge either cubed or crushed ice. Switch  222  is typically an SPST or SPOT switch (SPST switch shown). While not illustrated, switch  222  is mounted to the front of the beverage dispenser  20  so that it is readily accessible by the customer.  
         [0094]     Control unit  220  may be a microcontroller, a PLA, a PGA or a set of discrete components. Based on the depression of lever arm  214  and the setting of switch  222 , control unit  220  selectively actuates the auger motor  70 , the bypass gate motor  84  and the ice crusher motor  144 . Control unit  220  controls the operation and speed of auger motor  70 , bypass gate motor  84  and crusher motor  144 . Control unit  220  also monitors the current draw of each motor to determine if an ice jam has occurred. If an ice jam does occur, control unit  220  is programmed to rotate auger  62  and/or crusher blade assembly  104  in a manner so as to free the ice jam, for example, by reversing the direction of rotation of one or both of auger  62  and crusher blade assembly  104 . Not illustrated is the power supply that supplies the energization signals to the motors  70 ,  84  and  144 .  
         [0095]     In some versions of the invention an agitator  224 , shown diagrammatically in  FIG. 10 , is rotatably mounted in the ice bin  24 . An agitator motor  226  is mounted to an outer wall of the ice bin  24 . The agitator motor  226  is connected to the agitator  224  for periodically rotating the agitator. Agitator  224  is so rotated to prevent the cubed ice in bin  24  from congealing into large blocks that cannot pass through the ice bin opening. In some versions of the invention, control unit  220  also regulates the actuation of the agitator motor  226 . Control unit  220  may be configured to actuate the agitator motor  226  whenever ice is discharged. In addition, or alternatively, the control unit  220  periodically actuates the agitator motor  226  independent of the discharge of ice.  
         [0096]     When an individual wants an iced beverage from dispenser  20 , he often initially fills the container with the desired quantity of ice. The individual first sets switch  222  to choose the form of ice desired for the beverage. If switch  222  is set to indicate a choice of cubed ice, control unit  220 , if it has not already done so, actuates the bypass gate motor  84  to cause the bypass gate main body  81  to retract away from the auger duct bypass opening  60 . Each time the bypass gate  80  is moved, it is moved a set distance. Therefore, for each extension and retraction of the bypass gate  80 , motor  84  is actuated for a set period of time.  
         [0097]     Once the signal from sensor  218  indicates that lever  214  is pivoted, the control unit  220  actuates auger motor  70 . The auger motor  70  rotates to cause a like movement of auger  62  and paddle blade  66 . This results in the movement of ice through the auger duct  42  from the end adjacent opening  46  towards the opposed end. Ice crusher motor  144  is not actuated. Consequently, a head of cubed ice develops in auger duct  42  adjacent the primary opening  56 . The ice downstream of this head in the auger duct  42  is, therefore, forced out of the duct through the open bypass opening  60 .  
         [0098]     The ice discharged from bypass opening  60  flows onto the ice chute second slide  164 . Gravity causes the ice to move down the second slide  164  onto the first slide  162  and be discharged through chute opening  198  into the waiting container.  
         [0099]     Alternatively, at the start of the ice dispensing process, switch  222  is set to cause crushed ice to be dispensed. If switch  222  is not already in this state, control unit  220 , upon sensing the change in switch state, actuates the bypass gate motor  84 . Specifically, the bypass gate motor  84  is actuated to move the bypass gate main body  81  over the duct bypass opening  60 .  
         [0100]     Once sensor  218  transmits a signal indicating lever  214  has been pivoted, control unit  220  causes the auger motor  70  to be actuated as described above. Also during this ice dispensing process, the control unit  220  actuates the ice crusher motor  144 . Thus, simultaneously, auger  62  moves ice towards the free end of the auger duct  42  and the ice crusher  28  is actuated. Once the ice reaches the free end of the auger duct  42 , the paddle blades  66  force the ice out of the duct through the primary opening  56 . The cubed ice is pushed against the rearwardly-directed face of the ice crusher head  94 . The rotating blades  114  break the ice and force the crushed ice slivers through slots  102 . The crushed ice then moves down the chute slide  162  and is discharged from chute opening  198 . The rotating crusher blades  114  also add velocity to the crushed ice, resulting in an improved crushed ice dispense rate from chute opening  198 .  
         [0101]     All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.  
         [0102]     The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.  
         [0103]     Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Technology Category: 2