The present disclosure generally relates to ice bins and ice scoops.
Ice bins are used to receive ice from an ice maker and store the ice until the ice is used. Ice bins often include a scoop for retrieving ice stored out of the bin without direct contact between ice and the user's hands. Scoops are typically placed on top of the ice when not in use. By putting an ice scoop on top of the ice, the scoop has a tendency to become cold to the user's touch, especially if the scoop has been in the bin for a significant amount of time. Further, when the scoop is placed on top of the ice during non-use, the creation of new ice has a tendency to bury the ice scoop, making it difficult for the user to find and requiring the user to dig through the ice, causing the user to become cold and potentially contaminating the ice.
In one aspect, an ice bin comprising a bin body is disclosed. The bin body comprises a lower portion, an upper portion, and a perimeter wall extending height-wise from the lower portion to the upper portion. The upper portion of the bin body defines an ice drop opening configured so that ice dropped from an ice maker supported above the ice bin is passable through the ice drop opening into the interior of the ice bin. The bin body further comprises an ice retrieval opening spaced apart from the ice drop opening for providing access to the interior of the ice bin. The perimeter wall also comprises a support plate configured to support an ice scoop on the interior of the perimeter wall by a magnetic force between the ice scoop and the support plate.
In another aspect, an ice storage and retrieval assembly comprising an ice bin is disclosed. The ice bin comprises a bin body, the bin body comprising a lower portion, an upper portion, and a perimeter wall extending height-wise from the lower portion to the upper portion. The upper portion of the bin body defines an ice drop opening configured so that ice dropped from an ice maker supported above the ice bin is passable through the ice drop opening into the interior. The bin body further comprises an ice retrieval opening spaced apart from the ice drop opening for providing access to the interior of the ice bin. The perimeter wall comprises a support plate for supporting an ice scoop comprising at least one magnetic element. The scoop is configured to support itself on the perimeter wall at a location in the interior of the ice bin overlying the support plate by a magnetic force between the ice scoop and the support plate.
In yet another aspect, a method of manufacturing an ice bin is disclosed. The method includes forming a liner and an outer shell of the ice bin, fitting the liner into the outer shell, fitting the support plate between the liner and the outer shell temporarily using an adhesive, and foaming the area between the liner and the outer shell with an insulation layer to permanently secure the support plate in position.
In another aspect, a method of using an ice bin and scoop is disclosed. The method includes first detaching the scoop from an inner surface of the ice bin by overcoming a magnetic force between the scoop and the ice bin by which the scoop is supported on the inner surface of the ice bin. Second, scooping ice that has been deposited by an ice maker into the bin out of the ice bin with the scoop. Third, reattaching the scoop to the inner surface of the ice bin such that the scoop is supported on the inner wall by a magnetic force between the scoop and the inner surface of the ice bin.
In another aspect, a method of making a scoop is disclosed. The method comprises forming a scoop comprising a magnet receiving enclosure having an open end, placing a magnet element into the magnet receiving enclosure through the open end, and joining a cap to the scoop over the open end of the magnet receiving enclosure such that the cap retains the magnetic element in the enclosure.
In another aspect, an ice maker appliance is disclosed. The ice maker appliance comprises an ice bin comprising a bin body and a front door assembly. The front door assembly comprises a shell, a liner, and a support plate. The ice maker further comprises an ice scoop comprising at least one magnetic or ferromagnetic element. The scoop is configured to be releasably supported on the front door assembly by a force of magnetic attraction between the ice scoop and the support plate.
Other objects and features of the present disclosure will be in part apparent and in part pointed out herein.
Corresponding reference numbers indicate corresponding parts throughout the drawings.
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The ice bin 100 further defines two openings, an ice drop opening 122 (broadly, ice drop area) and an ice retrieval opening 124 (broadly, ice retrieval area). The upper portion 114 surrounds the ice drop opening 122 and is configured to form a seat. The ice drop opening 122 is configured so that ice formed in an ice maker (not shown), supported above the ice bin 100 on the seat of the upper portion 114, is passable through the ice drop opening into the ice bin. Once the ice from the ice maker has passed through the ice drop opening 122, it rests in the interior of the liner 120 for future use. The ice is then retrieved from the interior of the liner 120 by a user through the ice retrieval opening 124. The ice retrieval opening is located generally at the front end of the ice bin 100, as illustrated in
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In general, each support plate 130 is configured to support the scoop 105 on the inner wall of the bin 100 via a force of magnetic attraction between the support plate and the scoop. In one or more embodiments, the support plate 130 can comprise a ferromagnetic material such as galvanized steel and the scoop 105 comprises a magnetic material configured to impart a force of magnetic attraction between the ferromagnetic scoop and the support plate. In another embodiment, the support plate 130 comprises a magnet and the scoop 105 comprises ferromagnetic material such that the support plate 130 is configured to impart a force of magnetic attraction to the scoop for holding the scoop on the wall of the bin. Hereafter, an exemplary embodiment will be described wherein each support plate 130 comprises a single monolithic piece of ferromagnetic material (e.g., galvanized steel) and the scoop 105 comprises one or more magnets. However, it is now understood that the use of magnetic and ferromagnetic material as between the bin and the scoop be reversed without departing from the scope of the disclosure.
The support plate 130 is generally configured to be supported on the liner in the upper front corner of the liner 120, such that the support plate is adjacent to the ice retrieval opening 124. The illustrated support plate 130 is supported in the upper front corner of the liner 120 such that there is basically no spacing between the support plate and the front of the liner or the support plate and the top of the liner. This positioning allows for the scoop 105, further described below, to be situated away from the ice drop path and out of the ice reservoir.
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The support plate 130 has a top-to-bottom height H1 between a top edge margin and a bottom edge margin. In one embodiment, the top-to-bottom height H1 is in an inclusive range from about 6 inches to about 36 inches (e.g., from about 8 inches to about 30 inches). In the illustrated embodiment, the bottom edge margin of the support plate 130 is spaced apart from the bottom of the liner 120 by a top-to-bottom spacing distance H3 in an inclusive range of from about 12 inches to about 36 inches (e.g., from about 16 inches to about 30 inches). In certain embodiments, the top-to-bottom spacing distance H3 is greater than the top-to-bottom height distance H1. The liner 120 itself has a top-to-bottom height H4. In one or more embodiments, the top-to-bottom height of the support plate H1 is in an inclusive range from about 10% to about 75% of the top-to-bottom height of the liner H4 (e.g., an inclusive range of from about 20% to about 50%). In certain embodiments, the top-to-bottom spacing distance H3 is in an inclusive range of from about 25% to about 90% of the top-to-bottom height of the liner H4 (e.g., an inclusive range of 50% to about 80%). In the illustrated embodiment, the upper front corner region of each support plate 130 is beveled to match the angle of the frame around the ice retrieval opening 124. Because of this bevel, the top edge margin of the plate 130 has a height H2 below the bevel that is less than the overall height H1. In certain embodiments, the height H2 is an inclusive range of 10% to 90% of the height H1. The beveled edge defines an angle A1 with the front edge of the plate 130, measured as the outside angle between the front vertical edge and the bevel edge. In one or more embodiments, the angle A1 is in an inclusive range of from about 190° to about 260°.
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An exemplary method of using the ice bin 100 and scoop 105 will now be briefly described below. An ice machine (not shown) is supported above the upper portion of the ice bin 100 for forming ice and depositing ice into the bin. When the ice is formed, the ice machine drops the ice through the ice drop opening 122 defined by the upper portion 114 and into the interior ice bin 100 defined by a liner 120. The liner 120 houses the ice within the interior until a future user desires its use. While in the liner 120, the ice is hindered from melting due to an insulation layer (not shown) disposed between the outer shell 118 and the liner. When the user decides to use the ice in the bin 100, the user opens the door 126. In the initial position, the scoop 105 is supported in a position on the liner 120 overlying the support plate 130. In this initial position overlying the support plate 130, the scoop 105 is also out of the path of ice being dropped through the ice drop opening 122. The scoop 105 is supported onto the liner 120 through the force of magnetic attraction between magnetic elements 146 in the scoop and the ferromagnetic material of the support plate. The user grabs the handle 138 of the scoop 105, and by applying force, overcomes the magnetic force between the magnetic elements 146 of the scoop 105 and the support plate 130 and frees the scoop from its supported position on the liner 120. The user then scoops ice out of the liner 120 using the scoop 105. The ice collects in the bowl 140 of the scoop 105 to facilitate transfer of the ice to a desired location. Once the user has dispensed the ice outside of the ice bin 100, the user places the scoop 105 in the area overlying the support plate 130 on the interior of the liner 120. In one or more embodiments, the liner 120 has a marking indicating the location of the support plate 130 so that the user can visualize where to place the scoop. The magnetic force between the magnetic elements 146 and the support plate 130 once again supports the scoop 105 on the interior of the liner 120. Alternatively, the user may utilize the scoop 105 in substantially the same way, only with the scoop being supported on the exterior surface of the outer shell 118 in the area overlying the upright support member 150.
An exemplary method of manufacturing an ice bin 100 as described above will now be briefly described below. The method includes steps of forming a liner 120, forming the outer shell 118, temporarily supporting the support plates 130 on the liner via double-sided tape, and fitting the liner in the shell and support plates in the space between the liner and the shell. The particular order of these steps is not critical. So in one or more embodiments, the liner 120 can be formed, then the support plates 130 can be temporarily secured to the liner, and then the shell can be assembled around the liner. In another embodiment, the liner 120 and outer shell 118 are each formed in suitable manufacturing processes, the support plates 130 are then temporarily secured to the liner, and then the assembly of the liner and the support plates is inserted into the shell. In yet another embodiment, the liner 120 and outer shell 118 are each formed in suitable manufacturing processes, the liner is then slipped into the outer shell, and then the plates are temporarily secured to the liner in the space between the liner and shell. Any suitable manufacturing processes can be used to form the liner 120 and the shell 118. In an exemplary embodiment, the liner 120 is formed in a blow molding process, from blow-molded plastic. The shell 118 may suitably be formed by assembling a sub-frame and then securing outer shell wall panels to the sub-frame vial suitable fasteners or mechanical tabs or hooks. As mentioned above, in an exemplary embodiment, the support plate 130 is temporarily fitted onto the liner 120 using an adhesive (e.g., a double-sided tape). After the support plate 130 is temporarily secured and the liner 120 is in the outer shell 118, an insulation layer is foamed in the space between the outer shell and the liner in order to insulate the bin 100 and permanently secure the support plate in position. For example, curable and flowable insulation material is imparted into the space so that it substantially fills the space and conforms to the support plates 130. The insulation material is then cured to provide a firm hold of the support plate 130 in the desired position.
An exemplary method of manufacturing a scoop 105 as described above will now be briefly described below. The method includes forming a scoop 105 comprising a magnetic element receiving enclosure 144 having an open end, placing a magnetic element 146 into the magnetic element receiving enclosure through the open end, and joining a cap 145 to the scoop 105 over the open end of the magnetic element receiving enclosure such that the cap retains the magnetic element in the enclosure. In one embodiment, the joining of the cap 145 comprises ultrasonic welding the cap to the scoop 105. The scoop 105 may be formed by molding the scoop, and the scoop is preferably comprised of plastic.
The inventors believe that the above-described ice bin 100 and scoop 105 provide several advantages. As compared with prior art bins in which an ice scoop was placed directly atop the ice, the bin 100 and scoop 105 of the present disclosure are believed to provide a much more sanitary way of holding the scoop at a convenient, ready-to-use position. Whereas placing a scoop directly atop ice runs a risk of transferring germs and other pathogens from a user's hands, to the scoop, and further to the ice in the bin, the illustrated ice bin 100 and scoop 105 enable the user to quickly and easily position the scoop at a ready-to-use position without direct contact with the ice. Moreover, as compared with prior art ice bins that include integrated brackets for supporting a scoop out of the way of the ice, the illustrated bin 100 and scoop 105 are believed to provide a much more convenient, user-friendly mechanism for supporting the scoop. The inventors have recognized that scoop-holding brackets inside an ice bin are often difficult to use (particularly for uses with physical limitations due to injury or disability) because they only allow the user to support the scoop at a particular location and orientation. By contrast, the illustrated support plates 130 provide a wide range of possibilities for where and how a user can support the scoop 105 on the side wall of the bin, out of contact with the ice and out of the way of ice maker operation.
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It will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. As various changes could be made in the above constructions and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.