Ice Machine With Reduced Footprint

Description

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation-in-part of and claims priority to U.S. patent application Ser. No. 17/854,330, filed on Jun. 30, 2022, which claims priority to U.S. Provisional Patent Application No. 63/217,002, filed on Jun. 30, 2021, the entirety of both are hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates in general to the field of ice machines. More particularly, the present invention relates to an ice machine that has a compact footprint. Additionally, the present invention relates to an ice machine that can quickly create bags of ice, allowing for less ice to be stored prior to bagging.

A variety of bulky ice machines are known in the art. Historically, ice machines consisted of large coolers where bags of ice that were manufactured at a different location are transported and delivered into the cooler. In addition to transportation costs, such a system oftentimes led to breaking of bags during delivery, melting of ice during the delivery process, and other undesired results.

More recently, ice machines had various components that allow ice to be manufactured and bagged within the machine, before being deposited into a storage section. These types of ice machines required a very large footprint to accommodate the bags of ice, as well as the components required to manufacture the ice, bag the ice, seal the ice in a bag, and deliver the sealed bag to a large storage compartment. Additionally, these machines typically had a large reservoir of ice held in a hopper after manufacture by an ice maker, but prior to bagging. In order to maintain that ice, additional components were oftentimes incorporated into the hopper to break up the ice, prevent it from thawing and refreezing, etc. Also, large storage compartments for bagged ice were filled with substantial quantities of ice that had to be manufactured and stored for extended periods of time to accommodate demand. For instance, these units were routinely larger than six feet in length and four feet in depth. These large storage compartments were necessary to meet demand because systems could only bag ice at relatively slow rates, such as four minutes per bag of ice or longer.

Apart from the large space required for installation and operation of these machines, which was problematic for many convenience and other stores that had limited amounts of space for such devices, the storage of large quantities of ice frequently resulted in stale bags of ice. Additionally, machines with large storage sections filled with bags of ice are often susceptible to theft.

A number of these deficiencies were addressed in U.S. patent application Ser. No. 16/432,531 titled “Ice Vending Machine and Related Methods”, which was filed on Jun. 5, 2019, which claimed priority to U.S. Application No. 62/681,328 titled “Ice Vending Machines and Related Methods”, which was filed on Jun. 6, 2018, the disclosure of both of which are hereby incorporated by reference. While these applications disclosed ice machines that were superior to the prior art described above, further improvements are desired.

For instance, there is a need for an ice machine having a significantly reduced footprint. Similarly, there is need for an ice machine that is capable of rapidly manufacturing ice and bagging the ice to meet demand. Flexibility in throughput is also desirable. Still further, ease in servicing an ice machine and ease in changing rolls of bags are sought after features. Overall, there is a need for an ice machine that is an improvement over the prior art.

SUMMARY OF THE INVENTION

In accordance with an embodiment of the invention, an ice machine includes a frame, a cabinet extending around the frame, at least one ice maker coupled to the frame, a first ice hopper located beneath the ice maker and configured to receive ice from the ice maker, an auger extending along a portion of the first ice hopper to move ice to an opening, and a second hopper configured to receive ice from the first ice hopper moved through the opening by the auger. The ice machine further includes a bagging system configured to receive ice from the second hopper, a cradle having a bottom and a plurality of sides configured to support and constrain a bag from the bagging system while the bag receives ice from the second hopper, and a retrieval section configured to receive the bag after the bag is filled with ice.

According to another aspect of the invention, the ice machine may further include a sealing system and a chute extending from and pivotable about the second hopper. The ice machine includes a pusher section configured to bias the bag of ice towards the sealing system to seal the bag of ice using the heating element. Further, the pusher section is configured to push against and pivot the chute about the second hopper. The sealing system may include a heating element, a pusher plate having an opening formed therein, and a biasing assembly coupled to the pusher plate. The pusher plate may be moved by the biasing assembly to expose the heating element for sealing a bag of ice.

According to yet another aspect of the invention, the ice machine may further include a roll of bags removably mounted to the frame, a motor configured to advance a portion of the roll of bags to the bagging system, and a sensor configured to scan each bag from the roll of bags. In turn, advancement of the roll of bags to the bagging system by the motor is terminated when the sensor detects an unverified bag design.

According to another aspect of the invention, the ice machine may also include a refrigerated storage section located beneath the bagging system. When ice is deposited from the second hopper into the bag contained within the cradle, the cradle may be rotated to deposit bags of ice into the refrigerated storage section. The ice machine may also include a cradle fill sensor located adjacent the cradle to monitor when the cradle is in a position to receive the bag.

According to yet another embodiment of the invention, the ice machine may also include a bag fill sensor to monitor when the bag is either full or partially full. In the instance when the bag fill sensor is blocked to determine that the bag is partially full, the auger is rotated a predetermined number of times to complete fill the bag. Further yet, the first hopper may be a drying hopper having a sloped bottom surface to drain water away from the second hopper.

In accordance with another embodiment of the invention, an ice machine may include at least one ice maker, a first ice hopper located beneath the ice maker and configured to receive ice from the ice maker, and an auger extending along a portion of the first ice hopper to move ice to an opening. The auger is configured to jog back and forth after a predetermined period of time. The ice machine further includes a second hopper configured to receive ice from the first ice hopper moved through the opening by the auger, a bagging system configured to receive ice from the second hopper, and a retrieval section configured to receive the bag after the bag is filled with ice.

According to another aspect of the invention, the auger moves forward a first number of rotations to move ice to the opening. After the first predetermined number of rotations, the auger moves backward a second predetermined number of rotations.

According to another aspect of the invention, the ice machine includes a hopper sensor configured to determine whether the hopper is below or above a predetermined fill level. When the hopper sensor determines that the hopper is above a predetermined fill level, the predetermined period of time is less than 40 minutes. When the hopper sensor determines that the hopper is below a predetermined fill level, the auger rotates forward to move ice to the opening after a second predetermined period of time. In such an instance, the second predetermined period of time is less than 20 minutes.

According to another aspect of the invention, the ice machine may also include a coated heating wired disposed within a drain line of the ice maker.

In accordance with yet another embodiment of the invention, an ice machine includes at least one ice maker, a bagging system configured to receive and bag ice from the at least one ice maker, and a storage section configured to receive the bag after the bag is filled with ice. The storage section includes a fill sensor to monitor the storage section. The ice machine further includes a controller. Upon determination by the fill sensor that the storage section being at or above a predetermined fill level for a predetermined period of time, the controller activates an alarm to notify a user.

According to another aspect of the invention, upon determination by the fill sensor that the storage section has been emptied to a predetermined empty level, the controller turns off the alarm.

According to yet another aspect of the invention, upon determination by the fill sensor that bags of ice in a first side of the storage section and a second side of the storage section exceed a predetermined fill ratio for a predetermined period of time, the controller activates an alarm to notify a user. In turn, upon determination that bags of ice in the first side of the storage section and the second side of the storage section no longer exceed the predetermined fill ratio, the controller turns off the alarm.

These and other aspects, advantages, and features of the invention will become apparent to those skilled in the art from the detailed description and the accompanying drawings. It should be understood, however, that the detailed description and accompanying drawings, while indicating preferred embodiments of the present invention, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof. It is hereby disclosed that the invention include all such modifications.

DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the invention are illustrated in the accompanying drawings in which like reference numerals represent like parts throughout, and in which:

FIG. 1 is an isometric perspective view of an inventive ice machine;

FIG. 2 is a first isometric perspective view of an ice storage and bagging section of the inventive ice machine of FIG. 1;

FIG. 3 is a second isometric perspective view of the ice storage and bagging section of the FIG. 2;

FIG. 4 is a third isometric perspective view of the ice storage and bagging section of the FIGS. 2 and 3;

FIG. 5 is a fourth isometric perspective view of the ice storage and bagging section of the FIGS. 2-4;

FIG. 6 is a cutaway isometric perspective view of the ice storage and bagging section where a roll of bags is replaced;

FIG. 7 is a cutaway isometric perspective view of the ice storage and bagging section once the new bag of rolls is installed;

FIG. 8 is a cutaway side elevation view taken about line 8-8 of FIG. 7;

FIG. 9 is a detailed cutaway side elevation view taken about line 9-9 of FIG. 8 where the roll of bags is threaded through the machine;

FIG. 10 is a detailed cutaway side elevation of FIG. 9 once a tension arm is pivoted to secure the roll of bags in place and once a pair of bag rollers advance the roll of bags about the machine;

FIG. 11 is a first cutaway side elevation view showing ice being moved through a first hopper into a second hopper of the present machine;

FIG. 12 is a second cutaway side elevation view showing ice being moved through the first hopper into the second hopper and a bag that is opened by a blower;

FIG. 13 is another cutaway side elevation view showing the ice being funneled into the bag;

FIG. 14 is a detailed cutaway side elevation view showing the bag being sealed by a sealing system;

FIG. 15 is a detailed cutaway side elevation view showing the bag being detached from the roll once it is sealed;

FIG. 16 is an isometric perspective view of a cradle holding the sealed bag of ice of FIG. 15;

FIG. 17 is an isometric perspective view of the cradle of FIG. 16 rotating to drop the sealed bag of ice into a storage section;

FIG. 18 is a schematic block diagram of elements within the ice machine associated with a controller;

FIG. 19 is a block diagram of a method for jogging an auger of the ice machine, according to the present invention;

FIG. 20 is a cross-sectional view of a drain line of the ice machine of the present invention;

FIG. 21 is a block diagram of a method of alerting a user to the fill level of a storage section of the ice machine, according to the present invention;

FIG. 22 is a block diagram of a method of alerting a user to uneven distribution of bags within a storage section of the ice machine, according to the present invention; and

FIG. 23 is a schematic block diagram of interconnected ice machines.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Illustrative embodiments of an ice machine in accordance with the present invention are shown in the figures. While many of the components associated with the ice machine and shown in the figures will be described herein, additional components, including those present in the prior art, could similarly be incorporated into the ice machine of the present invention.

Turning initially to FIG. 1, the ice machine 50 includes a durable cabinet 52 and frame 54 contained within the cabinet 52. The cabinet 52 has four sides 56, including at least one side having a maintenance door or panel 58 that can be opened by an attendant. The maintenance door 58 may take up a full side, although it could also be limited to only a portion of the side. The ice machine 50 could have multiple maintenance doors (not shown) for access to different portions of the interior of the ice machine 50. Additionally, the cabinet 52 preferably has at least one ice retrieval door 60 that allows a customer to retrieve a bag 62 of ice 51 once it is ready or otherwise available. The ice retrieval door 60 may be locked until a bag 62 of ice is ready or payment is received. Preferably, apart from the ice retrieval door 60, the ice machine 50 is sealed such that the interior of the machine 50 cannot be accessed unless the maintenance door or panel 58 is opened. The retrieval door 60 may be made of the same material as the cabinet or as shown in the figures it may be a glass door allowing customers to see inside the machine 50 to ascertain the availability of bags of ice or to see when a bag of ice has completed filling.

Additionally, the ice machine 50 has at least one ice maker 64 mounted to the frame 54. As shown, the ice maker 64 is mounted towards the top of the frame 54, although it could be mounted elsewhere. A variety of different ice makers 64 may be installed depending on the quantity of ice 51 that is needed on a routine basis. By way of example and not limitation, potential ice makers include a KM-1301 SAJ Hoshizaki ice maker, which makes up to 1,300 pounds of ice per 24 hours, Hoshizaki model KM-1601 SAJ, which makes up to 1,600 pounds of ice per 24 hours; Hoshizaki model KM-1900 SAJ, which makes up to 1,900 pounds of ice per 24 hours; Hoshizaki model KM-2200 SRJ3, which makes up to 2,200 pound of ice per 24 hours; or Hoshizaki model KM-2600 SRJ3, which makes up to 2,600 pounds of ice per 24 hours. In terms of selection of the appropriate ice maker, for ice machines 50 located at high-demand locations, a higher quality, and thus faster operating ice maker 64 is preferable. This ensures that the ice maker 64 is capable of manufacturing ice 51 quickly enough to fill the bags 62. Additionally, or alternatively, multiple ice makers 64 may be mounted to the frame 54 for high-demand locations. For instance, two KM-2600 ice makers on one system can produce up to 5200 pounds of ice per day, enough to bag 520 ten-pound bags a day despite the relatively small footprint of the ice machines described herein.

For locations having less demand, slower throughput ice makers 64 may be used. Additionally, the ice makers 64 need not be permanently mounted to the frame 54 to permit flexibility in replacing the ice maker(s) 64 in the field to meet the demand of a given location. This customizability allows the characteristics of the ice machine 50 to be changed based on analytics or other criteria used to determine the demand at a given location.

Still looking to FIG. 1, in one embodiment of the present invention, an ice storage and bagging section 65 is located directly beneath the ice maker 64. The ice storage and bagging section 65 is shown in isolation with the sides removed to expose the interior components in FIGS. 2-15. The ice storage and bagging section 65 includes a frame 67 having various other components described herein mounted thereto. The maintenance door 58 described above is removably secured to the frame 67 to prevent unauthorized access to the interior of the frame 67. In the illustrated embodiment, the ice maker 64 is mounted to the top of the frame 67.

Once the ice 51 is made by the ice maker 64, it is dropped into a first hopper 66 of the ice storage and bagging section 65 that is located beneath the ice maker 64. As shown in FIGS. 2-5, the first hopper 66 has an upper section 68 that is substantially triangular in shape and having three sloped sides 72a, 72b, 72c down to a lower section 74 to form a funnel shape. The sloped sides 72a, 72b, 72c funnel and move the ice 51 downwardly. Additionally, the first hopper has an opening 78 formed therein, with the opening being located towards the upper section 68 between the first side 72a and second side 72b. The first hopper 66 is oriented to allow water to drain away from the ice 51, such that water is not transferred into a bag when the ice 51 is deposited into the bag 62. More specifically, the sides 72a, 72b, 72c are sloped downwardly away from the opening 78. In this way, the first (drying) hopper 66 can be used to funnel water out of the system. To facilitate this functionality, there is a drain 76 formed in the lower section 74 that allows the water to be drained out of the first hopper 66. The drain 76 is located in the lower section 74 of the first hopper 66 and is routed to a floor drain or sump pump. In this configuration, water is harvested and drained off the ice cubes 51 before they are moved to a second hopper described below.

The first hopper 66 has a capacity of between 35-95 pounds of ice, more preferably between 50-80 pounds of ice, and most preferable approximately 65 pounds of ice. In contrast to ice machines of the prior art, the first hopper 66 has a reduced footprint, and is oriented in a particular manner relative to the cabinet 52 so that the cabinet 52 only needs to be 34 inches in depth. This allows the ice machine 50 to fit in a standard grocery store aisle, while still having sufficient capacity to manufacture and bag ice at a high speed.

Preferably sensors (not shown) are located within the first hopper 66. In one preferred embodiment, a first sensor is located near the top of the first hopper. When the first sensor is covered by ice, the ice maker is deactivated to avoid excessive manufacture of ice. Once the first sensor is uncovered, the ice maker is reactivated to ensure that sufficient amount of ice is present in the first hopper 66 for ice to be bagged and dispensed and/or stored.

The first hopper 66 includes an auger 80 that moves ice 51 from the lower section 74 to the opening 78 and into a second hopper 94 as best seen in FIG. 11. The auger 80 is positioned to extend along the first and second sidewalls 72a, 72b from the lower section 74 up to the opening 78 as seen in FIGS. 3, 8, and 11-13. The lower section 74 is inclined away the opening 78 such that water is drained away from the opening 78 as described above. The auger 80 includes a shaft 82 and a corkscrew 84 configured to move ice 51 upwardly along the first hopper 66 and out of the opening 78 when the auger is rotated. The auger 80 can be powered by a motor 86 that is mounted to the frame 67 directly adjacent to the first hopper 66 next to the third wall 72c. In one preferred embodiment of the present invention, the motor 86 is the ¼ horsepower motor, model number B162FT-G2 described above.

As shown in FIGS. 2-5 and 11-13, the ice machine 50 also has a second hopper 94 into which ice is deposited from the first hopper 66. The second hopper 94 has four sides 96a, 96b, 96c, 96d with a funnel 88 at the bottom which is sloped towards an opening 90 through which the ice is funneled to a chute 89 into a bag 62 using a bagging system 98 that will be further described below. As such, the second hopper 94 serves as a chute that guides ice through the opening 90 into a bag 62. Additionally, the second hopper 94 may also include a blower opening 92 formed in the funnel 88 directly adjacent to the opening 90. The blower opening 92 is configured to blow air through the opening 90 in order to open a bag 62 in order to prepare the bag 62 for delivery of ice 51 as seen in FIG. 12. In such an embodiment a blower motor 91 is connected to the blower opening 92 by a hose 93.

While many of the components associated with the bagging system 98 are showed in U.S. application Ser. No. 16/432,531, which is incorporated herein by reference, some components are different and/or improved as will further be described below. The bagging system 98 includes a bagging motor 100 that rotates first and second bag rollers 101a, 102b to move a bag 62 into position prior to the filling of the bag 62 with ice, as well as a sensor 103. The bagging motor 100 is configured to move a bag or bags 62 quickly off of a roll 102 of bags to ensure high-speed filling of the bags 62 of ice. The sensor 103 is preferably configured to read a printed message, logo, bar code, etc. that is printed on the bag 62 while the bag 62 is moved into position about a viewing area 105 of the sensor 103. An encoder is preferably connected to the sensor 103 that ensures that the bags 64 are from an authorized provider. In a preferred embodiment, the roll of bags 102 is rotated a specified amount depending on whether the sensor is blocked or unblocked. For instance, the bag feed motor 100 may be a stepper type motor, where the roll 102 of bags is rotated a certain number of “clicks” depending on when the sensor is blocked or unblocked to position a new bag for filling. In the event that the sensor 103 and encoder are unable to verify that the bags 64 are from an authorized provider because the message, logo, bar code, etc. are not correct, the machine 50 can be powered down and an error message can be displayed until a user is able to realign the roll of bags 102 such that the sensor 103 confirms they are from an authorized provider.

As best shown in FIGS. 6 and 7, the roll of bags 102 are held in place by first and second arms 104, 106. The first and second arms 104, 106 are mounted within the cabinet 52 to the frame 67. Each of the arms 104, 106 have a slot 108, 110 formed therein. The slots 108, 110 are located at the top of the arms 104, 106 and face an exterior of the cabinet 52 so as to enable quick and easy installation of a fresh roll of bags 102 once the front maintenance panel 58 is removed. To install a fresh roll of bags 102, opposite ends 114 of a rod 112 extending through the roll of bags 102 are engaged into the slots 108, 110. The roll of bags 102 is then routed around through multiple guider rolls 116 as can be seen in FIGS. 9 and 10. For instance, as shown the roll of bags 102 are routed under first and second guider rolls 116a, 116b, and then over a third guider roll 116c before being secured between the bag rollers 101a, 101b. Of course, additional or fewer guider rolls could be included to ensure smooth and efficient deliver of the bags from the roll of bags 102 to the bagging system 98. Additionally, the illustrated embodiment includes a tension arm 118 configured to be lifted when a fresh roll of bags 102 are installed, and the biased downwardly directly adjacent one or more of the guider rolls 116 once the roll of bags 102 have successfully been installed and engaged with the bag rollers 101, such that the bags 102 are secured between the guider rolls 116 and the tension arm 118. As shown, the second roller 116b is affixed to the tension arm 118. The bag of rolls 102 are advanced through the system using the bag rollers 101 as shown in FIG. 10.

Once the bag has been filled by the bagging system 98, the bag 62 is sealed using a sealing system 120. The sealing system 120 may be similar to that shown and described in U.S. application Ser. No. 16/432,531, although some components are different and/or improved as described below. In the illustrated embodiment, the sealing system 120 includes a heating section 122 and a chute pusher section 124, as can best be seen in FIG. 14. The heating section 122 includes a heating element 126 that is heated to a desired temperature in order to seal the bag 62. The heating element 126 is surrounded and protected by a pusher plate 128. The illustrated pusher plate 128 includes a vertical portion 130, an opening 132 in the vertical portion 130, and an angled portion 134. When the bag 62 is ready to be sealed, the pusher plate 128 is moved away from the chute pusher section 124 so that vertical portion is moved away from the chute pusher section 124 while the heating element 126 remains in the same location, best seen in FIG. 14. As a result of this movement of the pusher plate 128, the heating element 126 moves through the opening 132 such that it is exposed. When this occurs, the bag 62 contacts the heating element 126 and is sealed by the heating element 126. For instance, the bag 62 may contact the heater element 126 for approximately 1-6 seconds, and more preferably approximately 3 seconds to ensure proper formation of the bag 62. Once the bag 62 is sealed, the pusher plate 128 may be returned to its initial position, such that again the vertical portion 130 surrounds and protects the heating element 126, as best seen in FIG. 15. The pusher plate 128 may be spring loaded in order for it to appropriately bias between the positions described above, although any other biasing mechanism could be used to achieve the same result.

In addition to the heating section 122, the chute pusher section 124 is also configured to help bias the bag 62 appropriately to ensure proper sealing of the bag. More specifically, the chute pusher section 124 includes components that enable movement of the chute 89 relative to the heating section. More specifically, the chute pusher section 124 includes a vertical portion 136 that is located directly adjacent to the chute 89. When the bag 62 is being sealed, a motor 138 connected to the vertical portion 136 by an arm 139 is activated to enable movement of the vertical portion 136. The vertical portion 136 presses against the chute 89 to move the chute 89, and the bag 62 resting upon the chute 89, towards the heating section 122. This further ensures the appropriate amount of contact between the bag 62 and the heating element 126 when the bag 62 is being sealed. The chute pusher section 124 may also include a horizontal element 140. The horizontal element 140 may include a perforated edge 142 that further assists in the separation of the bag 62 once the bag 62 is sealed. Additionally, to further assist with the separation of the bag 62 once the bag 62 is sealed, the bag rollers 101 may be rotated in the reverse direction once the bag 62 is sealed to break the seal between the formed bag 62 and the remaining roll of bags 102. Once the bag 62 has been sealed, the motor 138 is reactivated in the opposite direction to return the chute pusher section 124 to its original position as shown in FIG. 15.

Next, the retrieval storage section 144 will be further described. More specifically, beneath the second hopper 94, the ice machine 50 has a storage section 144 for stacking and storing bags. More specifically, the frame 67 may be mounted to the storage section 144. Since the bags 62 may be stored for extended periods of time, the storage section 144 is insulated and cooled to an appropriate temperature to maintain the ice in solid form. As such, bags 62 of ice may be manufactured until the storage section 144 is partially or substantially filled depending on the settings of the machine 50. Preferably, the interior of the storage section 144 has a fill sensor 146. The ice machine 50 continues creating bags 62 of ice until the fill sensor 146 is triggered. In one preferred embodiment of the present invention, the fill sensor 146 is in the upper 25% of the storage section 144. Once the fill sensor 146 has been blocked, the manufacture of ice and filling of bags 62 can be stopped. Once enough bags 62 of ice have been removed from the storage section 144, the fill sensor 146 will no longer be triggered, in which case the production of bags 62 of ice will resume until the fill sensor 146 is again triggered, at which point manufacture is again suspended.

Additionally, the ice machine 50 has a cradle 148 which supports the bags 62 as they are filled with ice, and then deposits the filled bag into the storage section 144. Preferably, as shown in FIGS. 13-17, the cradle 148 has a bottom 150, and front and back sides 152, 154 to hold the bag 62 in place. In a preferred embodiment, a cradle fill sensor 156 is located adjacent to the cradle 148 to monitor when the cradle 148 is in a position to receive a bag 62 and fill it with ice. An unfilled bag 62 extends into the cradle 148. The bag 62 is then opened preferably using a blower motor 91 with air that is transported by the hose 93 to the blower opening 92 to allow ice to enter into the mouth of the bag 62. See FIG. 13. While the bag 62 remains in the cradle 148, ice is moved from the first hopper 66 using the auger 80 to the second hopper 94, after which the ice will fall downwardly into the bag 62 as seen in FIG. 13.

Preferably a bag full sensor 158 is present that monitors the fill level of a bag 62 that is contained within the cradle 148. In one preferred embodiment, the sensor 158 senses when the bag 62 is partially, but not completely full once the sensor 158 is blocked. When the sensor is blocked, the auger 80 continues to rotate by a control panel a specific number of times to ensure the bag 62 is filled to the appropriate level. By way of example, when a 10-pound bag of ice is desired, the bag 62 can be filled until the sensor 158 detects that 8 pounds of ice are in the bag 62. Thereafter, the auger 80 is rotated a predetermined number of additional rotations to deposit two additional pounds of ice to result in the desired 10-pound bag of ice. Such a configuration results in more accurate bag weight regardless of how much ice is contained in the first hopper 66.

Regardless of when the bag 62 is determined to be full, it is sealed as described above and then prepared for deposit into the storage section 144. As shown, the cradle 148 is connected to a motor 159 with a drive chain 160. More specifically, the drive chain 160 rotates the cradle 148 in a first direction until the bag 62 slides out of the cradle 148 and into the storage section 144 as shown in FIG. 17. Once the bag 62 has been deposited into the storage section 144, the motor drives the drive chain 160 in the opposite direction to return the cradle 148 to the original position so that additional bags 62 can be produced. As described above, bags 62 are continually made until the fill sensor 146 has been blocked.

As shown in the figures and described above, the ice machine 50 has a compact size compared to traditional ice machines that required a large footprint. More specifically, the ice machine 50 has exterior dimensions of approximately 48 inches wide by 32 inches deep by 110 inches in height, with the interior dimensions being 44 inches wide by 28 inches deep. Having such a small footprint is beneficial in that the ice machine of the present invention can rest on a standard shelf or fit in the space of a standard shelf of a grocery or convenience store. Because the ice machine 50 is approximately 48 inches wide, it is as wide as a standard grocery store shelf. The reduced footprint means that there is less space to store ice in a hopper 66. However, the combination of the speed with which the ice maker 64 makes ice and the power of the motors associated with the auger 80 and other components, the ice machine 50 is still capable of quickly filling, sealing, and delivering bags of ice as described above and minimal if any ice is stored in hopper 66.

The ice machine 50 has been optimized for quickly bagging the ice, while having a relatively small footprint. For instance, in a preferred embodiment, the ice machine is equipped to make a 10-pound bag of ice in approximately 15 seconds. In other embodiments, a 10-pound bag of ice is made in less than 15 seconds. In still other embodiments, a 10-pound bag of ice is made in less than 30 seconds.

In the illustrated embodiments, the machine 50 is operated using a user interface 162 mounted to the cabinet 52, such as a touch panel. In alternative embodiments, the machine is configured to communicate electronically with external communication devices such that bags 62 of ice can be ordered remotely, for instance by paying a cashier, ordering a bag on a phone or tablet application, ordering a bag online, or any other way known to those having ordinary skill in the art.

While the storage section 144 is shown to be insulated and refrigerated, other components of the machine could also be insulated and refrigerated if desired.

Additionally, in certain preferred embodiments, the ice machine is delivered in multiple sections and later assembled. For instance, the storage section 144, the ice storage/bagging section 65 and associated components including the hoppers 66, 94 and bagging system 98, and the ice makers 64 could be assembled on site. Additionally, as mentioned above, the ice makers 64 may be changed or the number of ice machines increased or decreased depending on the needs of a given location. Further still, various machines 50 and associated components may be in communication with one another. For instance, when one machine 50 is low on ice or out of ice, a notification may be transmitted so that individuals may physically move filled bags 62 of ice from a location having a surplus to the location that has an insufficient number of filled bags 62 of ice. The machines 50 and associated systems may be configured to allow for and track this borrowing of bags from one to another. Live, online data may be used to monitor such activities and ensure sufficient supply to all machines 50. Further still, live, online data may be used for other purposes, including to plan for preventative maintenance, track operation and breakdown of different components, identify machines that need to be replaced or exchanged with larger or smaller ice makers, and the like in order to optimize operation of machines 50 in general and at specific locations.

In a preferred embodiment of the invention, the previously discussed sensors within the first hopper 66 may include a level sensor 200 to determine the level of ice within the first hopper 66. Preferably, the level sensor 200 determines whether the level of ice within the first hopper 66 is above or below a predetermined fill level of the first hopper 66.

As shown in the system block diagram of FIG. 18, the level sensor 200 may be in communication with a controller 202 of the machine 50. Further, the controller 202 is in communication with the auger 80 and is configured to operate the auger 80 in a number of scenarios, some of which will be described below in further detail. As also shown in FIG. 18 and will be discussed later in further detail, the controller 202 may also be in communication with the fill sensor 146 disposed within the storage section 144 and an alarm 204 of the machine 50.

To prevent bridging of the ice within the hopper 66, the auger 80 in the first hopper 66 auto-jogs a number of rotations back and forth when the level sensor 200 senses that the level of ice within the first hopper 66 is at or above the predetermined fill level. That is, the motor 86 driving the auger 80 may be a bi-directional motor that can cause the auger 80 to rotate both forward and backward.

As shown in the method 300 of FIG. 19, at block 302 the controller 202 communicates with the level sensor 200 to determine if the ice within the first hopper has been at or above the predetermined fill level for more than a predetermined period of time. If yes, the controller 202 proceeds to block 304 and operates the auger 80 to auto-jog back and forth two rotations to move the ice within the first hopper 66 and prevent it from bridging. In varying embodiments of the invention, the auger 80 may be auto-jogged more or less than two rotations back and forth in such a scenario.

In a preferred embodiment of the invention, the first hopper 66 is sized to hold enough ice to fill three bags of ice. In such an embodiment, it is preferred that the preferred predetermined fill level of the first hopper 66 is above 33% to signify whether there is enough ice to fill one bag or more than one bag. Even more preferably, the predetermined level of the hopper is at or around 50% of the hopper. Further yet, the preferred predetermined amount of time is preferably 40 minutes or less to prevent the ice within the hopper from bridging. More preferably, the predetermined amount of time is 30 minutes or less.

Referring again to the method 300 of FIG. 19, if the answer to block 302 is no, the controller 202 proceeds to block 306. At block 306, the controller 202 communicates with the level sensor 200 to determine if the level of ice within the hopper is below the previously discussed predetermined level for more than another predetermined amount of time. Preferably, this predetermined amount of time is 20 minutes or less. More preferably, this predetermined amount of time is 10 minutes of less.

If yes, the controller 202 proceeds to block 308 and the auger 80 is rotated forward to fill a subsequent bag of ice and empty the first hopper 66. If no, the method 300 resets and the controller 202 returns to block 302. In varying embodiments of the invention, the controller 202 may start with block 302, as described above, block 306, or proceed with blocks 302 and block 306 simultaneously.

In another preferred embodiment of the invention, the controller 202 operates the auger 80 to prevent ice from remaining at a top edge of the first hopper 66 and inadvertently falling into the second hopper 94. For example, upon rotating the auger 80 to transfer ice from the first hopper 66 to the second hopper 94 for filling a bag, the controller 202 may further cause the auger 80 to rotate backward one or more rotations so that ice remaining on the corkscrew 84 of the auger 80 is lowered from the top edge of the first hopper 66.

Referring again to the ice maker 64 of the machine 50, the ice maker 64 may include a condensing unit and an evaporator for making ice. As these elements are generally known in the art, they are not specifically shown in the drawings. In most cases, the condensing unit includes an evaporating drain line to remove excess water from the ice maker 64 to prevent leaking and damage to the ice maker 64.

FIG. 20 illustrates a cross-sectional view of a drain line 210 according to an embodiment of the invention. To prevent freezing of the drain line 210, a coated wire 212 may be inserted into the drain line 210. The coated wire 212 includes a heating wire 214 surrounded by a coating 216. The coating 216 is preferably a waterproof coating to protect the heating wire 214 from the environment within the drain line 210. Preferably, the heating wire 214 is a resistance heating wire that generates heat when exposed to a power source. In turn, the heating wire 214 of the coated wire 212 maintains the drain line 210 at a temperature above freezing to prevent blocking of the drain line.

Referring again to fill sensor 146 disposed within the storage section 144 of the machine 50, the fill sensor 146 may be in the form of a lidar sensor or other sensor to gain a 3D model of the interior of the storage section 144. It is contemplated that the fill sensor 146 may be located at the top of the storage section 144 and facing downward as opposed to the location show in FIGS. 16 and 17. In turn, the fill sensor 146 is able to provide an accurate mapping of how the storage section 144 is being filled with bags of ice from the bagging section 65.

Further, the machine 50 may include an alarm 204 to notify an individual when action needs to be taken with respect to the machine 50. For example, the alarm 204 may be associated with the user interface 162 of the machine 50. In a preferred embodiment of the invention, the alarm 204 may be activated by the controller 202 by a number of scenarios identified by the fill sensor 146.

As shown in the method 400 of FIG. 21, at block 402 the controller 202 communicates with the fill sensor 146 to determine whether the storage section 144 is filled to a predetermined fill level or percentage. If yes, the method 400 proceeds to block 404. If no, the method 400 starts over.

At block 404, the controller 202 determines whether the storage section 144 has been filled to the predetermined fill level or percentage for a predetermined period of time. Preferably, the predetermined period of time is less than 10 minutes, and the predetermined fill level or percentage is at or above 90%. Even more preferably, the predetermined period of time is less than 5 minutes. If yes, the method 400 proceeds to block 406. If no, the method 400 returns to block 402.

At block 406, the controller 202 causes the alarm 204 to notify an individual that the storage section 144 is full. In turn, the individual is able to remove bags of ice from the storage section 144 to a backstock area (not shown).

At block 408, the controller 202 determines whether the storage section has been emptied to a predetermined transition or empty level. If yes, the method 400 proceeds to block 410 and the controller 202 causes the alarm 204 to stop. If no, the method 400 returns to block 406 and the alarm 204 is kept on. In preferred embodiments of the invention, the predetermined transition level may be at or below 10%. Even more preferably, the predetermined transition level of the storage unit 144 is empty.

As shown in FIG. 17, the storage section 144 may be sized to contain multiple rows of bags of ice 62. As the bags 62 are deposited in the storage section 144, they may accumulate more to one side than the other. Alternatively, purchasers may take bags 62 from one side of the storage section 144 more than the other. If one side of the storage section 144 fills up with bags 62 faster than the other, the bags 62 within the storage section 144 may stack high enough on one side to interfere with the cradle 152, while a portion of the storage section 144 remains unfilled.

A method 500 shown in FIG. 22 illustrates a method of alerting an individual due to an unbalanced arrangement of bags 62 within the storage section 144. At block 502, the controller 202 communicates with the fill sensor 146 whether the bags 62 within the storage section 144 are evenly distributed between a first side 144a and a second side 144b of the storage section 144. If no, the method 500 proceeds to block 504. If yes, the method 500 starts over.

Determination of whether the first side 144a and the second side 144b are evenly distributed may be in the form of a predetermined fill ratio between the two sides 144a, 144b. Preferably, the predetermined fill ratio may be 4:1 or less. In such an instance, if the first side 144a has four times as many bags of ice 62 than the second side 144b or vice versa, the predetermined fill ratio is satisfied and the controller 202 determines that the bags of ice 62 within the storage section 144 are not evenly distributed.

Even more preferably, the predetermined fill ratio may be 2:1 or less. That is, if the first side 144a has twice as many bags of ice 62 than the second side 144b or vice versa, the predetermined fill ratio is satisfied and the controller 202 determines that the bags of ice 62 within the storage section 144 are not evenly distributed.

At block 504, the controller 202 determines whether bags of ice 62 within the storage section 144 are evenly distributed between a first side 144a and a second side 144b for a predetermined period of time. Preferably, the predetermined period of time is less than 30 minutes. Even more preferably, the predetermined period of time is less than 15 minutes. If yes, the method 500 proceeds to block 506. If no, the method 500 returns to block 502.

At block 506, the controller 202 causes the alarm 204 to notify an individual that the bags of ice 62 are not evenly distributed between the first and second sides 144a, 144b of the storage section 144. In turn, the individual is able to redistribute and organize the bags of ice 62 within the storage section 144.

The method 500 then proceeds to block 508. At block 508, the controller 202 again determines whether the bags 62 within the storage section 144 are evenly distributed between a first side 144a and a second side 144b of the storage section 144. If yes, the method 500 proceeds to block 510 and the controller 202 causes the alarm 204 to stop. If no, the method 500 returns to block 506 and the alarm 204 is kept on. For example, once the predetermined fill ratio is no longer satisfied, the method 500 may proceed to turn off the alarm 204.

As shown in FIG. 23, it is also contemplated that the ice machine 50 may be connected to a server 602 (such as a cloud-based sever) or a monitoring device 604 via a wide area network (WAN) 606, typically via the Internet. Preferably the monitoring device 604 is located at a separate location from the ice machine 50 and is able to connect to multiple ice machines 50 in various locations through the WAN 606. It is also contemplated that the monitoring device 604 may be in communication with the server 602 via the WAN 606 and via an alternative wireless or wired communication line 608. The monitoring device 604 may be in the form of computer, laptop, tablet, smart phone, or other similar devices.

The monitoring device 604 is contemplated to allow interaction with the controllers 202 of connected ice machines 50 and may include permissions not found in the user interface 162 of a specific ice machine 50. Such permissions may include the ability to activate and deactivate the alarm 204 outside of the methods 400, 500 discussed above. Further yet, the monitoring device 604 may also be able to interact with the controller 202 to activate the motor 86 and the auger 80 to remotely fill bags of ice 62, jog the auger 80 back and forth, or otherwise move the auger 80 as desired.

The monitoring device 604 may also be able to adjust the permissions of the user interface 162 of a specific ice machine 50 to allow users of that specific ice machine 50 to have greater control. For instance, the monitoring device 604 may provide the user interface 162 of a specific ice machine 50 the capability of interacting with the controller 202 to activate and deactivate the alarm 204 outside of the methods 400, 500 discussed above, to activate the motor 86 and the auger 80 to remotely fill bags of ice 62, jog the auger 80 back and forth, or otherwise move the auger 80 as desired.

It should be understood that the above description, while indicating representative embodiments of the present invention, is given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications.

Various additions, modifications, and rearrangements are contemplated as being within the scope of the following claims, which particularly point out and distinctly claim the subject matter regarding as the invention, and it is intended that the following claims cover all such additions, modifications, and rearrangements.