Ice distribution system and method

• US 8,381,534 B2
• Filed: 05/30/2008
• Issued: 02/26/2013
• Est. Priority Date: 05/31/2007
• Status: Active Grant

• Current Assignee: Reddy Ice LLC
• Original Assignee: Reddy Ice Corporation (Stone Canyon Industries Holdings LLC)
• Inventors: Metzger, Mark C.
• Primary Examiner(s): Tyler, Cheryl J
• Assistant Examiner(s): ROGERS, LAKIYA G
• Application Number:
  US12/130,946
• Publication Number:
  US 20080295462A1
• Time in Patent Office: 1,733 Days
• Field of Search: 62/60, 623/44, 621/37, 414/792.7
• US Class Current: 62/60
• CPC Class Codes: B65B 1/04 Methods of, or means for, filling the material into the containers or receptacles
• CPC Class Codes: B65B 1/30 Devices or methods for controlling or determining the quantity or quality or the material fed or filled
• CPC Class Codes: B65B 39/007 Guides or funnels for introducing articles into containers or wrappers
• CPC Class Codes: B65B 43/52 using roller-ways or endless conveyors
• CPC Class Codes: B65G 47/32 Applications of transfer devices such devices per se B65G47/74
• CPC Class Codes: F25C 1/00 Producing ice F25C3/00 takes precedence
• CPC Class Codes: F25C 5/187 with ice level sensing means
• CPC Class Codes: F25C 5/24 for storing bins ice bins F25C5/182

Abstract

An ice distribution system and method according to which ice-filled bags are distributed within a unit such as, for example, an ice merchandiser.

Claims

1. A method comprising:

distributing a first ice-filled bag within an internal region defined by a temperature-controlled storage unit, comprising;

providing a first kicker assembly comprising a first basket, wherein the first kicker assembly is movable within the internal region;

disposing the first ice-filled bag in the first basket of the first kicker assembly, wherein the first ice-filled bag is adapted to be dropped within the internal region as a result of being discharged from the first kicker assembly;

searching for an available space in the internal region in which to dispose the first ice-filled bag, comprising;

coupling a first sensor to the first kicker assembly so that the first sensor is movable with the first kicker assembly;

moving the first kicker assembly, and thus the first ice-filled bag and the first sensor, within the internal region; and

determining, using the first sensor, that there is not a second ice-filled bag immediately below the first kicker assembly and at a location within the internal region towards which the first ice-filled bag would be dropped if the first ice-filled bag were to be discharged from the first kicker assembly, thereby identifying the location as the available space in the internal region;

and

disposing the first ice-filled bag in the available space in the internal region, comprising;

dropping the first ice-filled bag within the internal region by discharging the first ice-filled bag from the first kicker assembly.

2. The method of claim 1 further comprising:

determining whether the temperature-controlled storage unit is full of bags filled with ice after distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit; and

if the temperature-controlled storage unit is not full of bags filled with ice after distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit, then;

(a) filling another bag with ice to thereby produce another ice-filled bag;

(b) distributing the another ice-filled bag within the internal region defined by the temperature-controlled storage unit; and

(c) if the temperature-controlled storage unit is not full of bags filled with ice after distributing the another ice-filled bag within the internal region defined by the temperature-controlled storage unit, then repeating steps (a) and (b) until the temperature-controlled storage unit is full of bags filled with ice.

3. The method of claim 1 wherein moving the first kicker assembly, and thus the first ice-filled bag and the first sensor, within the internal region comprises:

extending one or more tracks within the internal region;

coupling the first kicker assembly to the one or more tracks;

operably coupling a drive motor to the one or more tracks; and

driving the one or more tracks using the drive motor to thereby move the first kicker assembly and thus the first ice-filled bag and the first sensor.

4. The method of claim 1 wherein dropping the first ice-filled bag within the internal region by discharging the first ice-filled bag from the first kicker assembly comprises:

rotating the first basket to thereby cause the first ice-filled bag to fall out of the first basket.

5. The method of claim 1 wherein the first kicker assembly further comprises a rotator motor operably coupled to the first basket;

and

wherein dropping the first ice-filled bag within the internal region by discharging the first ice-filled bag from the first kicker assembly comprises;

activating the rotator motor to rotate the first basket and thereby cause the first ice-filled bag to fall out of the first basket.

6. A method comprising:

distributing a first ice-filled bag within an internal region defined by a temperature-controlled storage unit, comprising;

providing a first kicker assembly comprising a first basket, wherein the first kicker assembly is movable within the internal region;

disposing the first ice-filled bag in the first basket of the first kicker assembly, wherein the first ice-filled bag is adapted to be dropped within the internal region as a result of being discharged from the first kicker assembly;

determining, using a first sensor, that there is not a second ice-filled bag immediately below the first kicker assembly and at a location within the internal region towards which the first ice-filled bag would be dropped if the first ice-filled bag were to be discharged from the first kicker assembly, thereby identifying the location as an available space in the internal region;

and

disposing the first ice-filled bag in the available space in the internal region, comprising;

dropping the first ice-filled bag within the internal region by discharging the first ice-filled bag from the first kicker assembly.

7. The method of claim 6 further comprising:

coupling the first sensor to the first kicker assembly so that the first sensor is movable with the first kicker assembly; and

moving the first kicker assembly, and thus the first ice-filled bag and the first sensor, within the internal region.

8. The method of claim 6 further comprising:

determining whether the temperature-controlled storage unit is full of bags filled with ice after distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit; and

if the temperature-controlled storage unit is not full of bags filled with ice after distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit, then;

(a) filling another bag with ice to thereby produce another ice-filled bag;

(b) distributing the another ice-filled bag within the internal region defined by the temperature-controlled storage unit; and

(c) if the temperature-controlled storage unit is not full of bags filled with ice after distributing the another ice-filled bag within the internal region defined by the temperature-controlled storage unit, then repeating steps (a) and (b) until the temperature-controlled storage unit is full of bags filled with ice.

9. The method of claim 6 wherein moving the first kicker assembly and thus the first ice-filled bag within the internal region comprises:

extending one or more tracks within the internal region;

coupling the first kicker assembly to the one or more tracks;

operably coupling a drive motor to the one or more tracks; and

driving the one or more tracks using the drive motor to thereby move the first kicker assembly and thus the first ice-filled bag.

10. The method of claim 6 wherein dropping the first ice-filled bag within the internal region by discharging the first ice-filled bag from thefirst kicker assembly comprises:

rotating the first basket to thereby cause the first ice-filled bag to fall out of the first basket.

11. The method of claim 6 wherein the first kicker assembly further comprises a rotator motor operably coupled to the first basket;

and

wherein dropping the first ice-filled bag within the internal region by discharging the first ice-filled bag from the first kicker assembly comprises;

activating the rotator motor to rotate the first basket and thereby cause the first ice-filled bag to fall out of the first basket.