U.S. patent application number 09/908226 was filed with the patent office on 2001-11-08 for method for dispensing a desired portion of frozen product.
Invention is credited to Fancher, Hershel Edward, Harpring, David Anthony, Ogburn, Patrick Joseph, Vincent, Michael James.
Application Number | 20010038019 09/908226 |
Document ID | / |
Family ID | 23391424 |
Filed Date | 2001-11-08 |
United States Patent
Application |
20010038019 |
Kind Code |
A1 |
Vincent, Michael James ; et
al. |
November 8, 2001 |
Method for dispensing a desired portion of frozen product
Abstract
A system dispenses a desired portion of frozen product at a
uniform rate from a product container containing the frozen
product. The product container has a spout, and a dispensing valve
connected to the spout to seal the product container. The
dispensing valve is used to control dispensing of the frozen
product from the product container. A label, attached to the
product container identifying the formulation of the frozen
product, is read to determine at least the formulation of the
frozen product. Based upon at least the formulation, a controller
controls the applied force from a drive and applied the force to a
piston in the product container in order to dispense the frozen
product at a uniform rate. The force is adjusted by the controller
such that the frozen product is dispensed at a uniform rate until
the desired portion is dispensed. The product container is
sufficiently rigid so as not to deform when the force is applied to
dispense the frozen product. The product container is also
sufficiently deformable so that the product container is
collapsible when it is empty of frozen product. Further, a product
volume sensor is provided to determine the amount of frozen product
in the product container and when the product container is empty of
frozen product.
Inventors: |
Vincent, Michael James;
(Pleasanton, CA) ; Fancher, Hershel Edward; (New
Albany, IN) ; Harpring, David Anthony; (Louisville,
KY) ; Ogburn, Patrick Joseph; (Louisville,
KY) |
Correspondence
Address: |
DORR CARSON SLOAN & BIRNEY, PC
3010 EAST 6TH AVENUE
DENVER
CO
80206
|
Family ID: |
23391424 |
Appl. No.: |
09/908226 |
Filed: |
July 18, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09908226 |
Jul 18, 2001 |
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09353983 |
Jul 15, 1999 |
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6264066 |
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Current U.S.
Class: |
222/95 ; 222/105;
222/146.6; 222/327 |
Current CPC
Class: |
B67D 2001/0811 20130101;
A23G 9/28 20130101; A23G 9/283 20130101; A23G 9/228 20130101 |
Class at
Publication: |
222/95 ; 222/105;
222/146.6; 222/327 |
International
Class: |
B65D 035/28 |
Claims
What is claimed is:
1. An apparatus for dispensing frozen product, said apparatus
comprising: (a) a product container containing said frozen product,
said product container comprising: a first end; a second end
opposite said first end; an interior portion bounded by said first
and second ends having an interior wall; a dispensing spout
connected to said first end; a piston movably positioned within
said interior portion and sealing said second end; a raised annular
edge located around a peripheral edge of said piston, said raised
annular edge slightly outwardly deforming said interior wall such
that said interior wall is cleaned of said frozen product when said
piston moves toward said first end; a support ring engaging said
second end of said product container, said support ring maintained
in a fixed position in relation to movement of said piston; (b) a
support structure connected to said apparatus and engaging said
support ring of said product container, said support structure
maintaining said support ring in said fixed position and holding
said product container in a dispensing orientation wherein said
first end is positioned below said second end; (d) a drive
mechanism that abuts said piston positioned within said product
container, said drive mechanism forcing said piston to move in a
direction of said first end, said movement of said piston
compressing said frozen product within said product container and
extruding said frozen product from said dispensing spout, wherein
said product container is sufficiently rigid such that said product
container is not deformed by movement of said piston and said
product container is sufficiently deformable such that said product
container is collapsible when said product container is empty of
frozen product.
2. The apparatus, as claimed in claim 1, wherein said product
container is composed of a flexible film laminate.
3. The apparatus, as claimed in claim 1, wherein said product
container is cylindrical.
4. The apparatus, as claimed in claim 1, wherein said product
container has a diameter ranging from about 6 to 8 inches and a
length ranging from about 10 to 12 inches.
5. The apparatus, as claimed in claim 1, wherein said piston is
circular.
6. The apparatus, as claimed in claim 1, wherein said piston is
composed of plastic.
7. The apparatus, as claimed in claim 1, further comprising: a
dispensing valve connected to said dispensing spout, said
dispensing valve regulating a flow of said frozen product extruded
from said dispensing spout.
8. A dispensing valve connected to a spout end of a product
container containing frozen product, said dispensing valve
comprising: a valve body attached to said spout end, said valve
body having a portion extending beyond said spout end; and a valve
gate attached to said portion of said valve body extending beyond
said spout end, said valve gate having an opening for dispensing
frozen product from said product container, said valve gate
positionable from a first position where said frozen product is
dispensed from said opening to a second position where said frozen
product is prevented from being dispensed from said opening,
movement from said first position to said second position shearing
said frozen product located within said portion of said valve body
positioned below said spout end, said dispensing valve being
attached to said spout end of said product container before or
after filling said product container with said frozen product to
seal said product container, and said dispensing valve also used to
control dispensing of said frozen product from said product
container.
9. The dispensing valve, as claimed in claim 8, further comprising:
a seal positioned between said valve body and said spout end to
prevent leakage of said frozen product.
10. The dispensing valve, as claimed in claim 9, wherein said seal
comprises an o-ring.
11. The dispensing valve, as claimed in claim 8, wherein said
opening in said valve gate has a predetermined shape wherein added
products freely flow from said opening.
12. The dispensing valve, as claimed in claim 11, wherein said
predetermined shape is selected from the group consisting of a
circle, star and square.
13. The dispensing valve, as claimed in claim 8, wherein said valve
gate comprises a plurality of openings and said valve gate is
positionable from a plurality of said first positions where said
frozen product is dispensed from one of said plurality of openings
to said second position where frozen product is prevented being
dispensed from said one of said plurality of openings.
14. The dispensing valve, as claimed in claim 8, wherein an
actuator is connected to said valve gate and moves said valve
gate.
15. A method for dispensing a desired portion of frozen product
from a product container, said method comprising the steps of:
providing information on said product container; reading said
information from said product container, said information relating
to said frozen product contained within said product container;
determining a force based on said information for dispensing the
frozen product at a uniform rate; applying said determined force to
said product container; and dispensing said frozen product from
said product container at a uniform rate.
16. The method, as claimed in claim 15, further comprising the step
of: determining a temperature of said frozen product contained
within a product container.
17. The method, as claimed in claim 15, wherein said step of
reading said information from said product container determines a
formulation of said frozen product contained within said product
container.
18. The method, as claimed in claim 15, further comprising the step
of: displaying a formulation of said frozen product.
19. The method, as claimed in claim 15, wherein said step of
applying a force further comprises the steps of: monitoring said
force applied to said product container in said step of applying a
force; and adjusting said force applied to said product container
in said step of applying a force based on said step of monitoring a
force.
20. The method, as claimed in claim 15, wherein said step of
dispensing said desired portion continuously dispenses said frozen
product until said desired portion has been dispensed.
21. The method, as claimed in claim 15, further comprising the step
of: maintaining said temperature of said frozen product at a
constant predetermined temperature.
22. The method, as claimed in claim 15, further comprising the step
of: determining when said product container is empty of said frozen
product.
23. An apparatus for dispensing a desired portion of frozen
product, said apparatus comprising: a product container containing
said frozen product, said product container having first and second
opposite ends, said first end having a piston movably positioned
therein, said second end connected to a dispensing spout; a plunger
connected to a drive mechanism, said plunger positioned to apply a
force to said piston, said force being supplied by said drive
mechanism and said force moving said piston to compress said frozen
product from said first end toward said second end of said product
container; a controller connected to said drive mechanism and
controlling said force applied to said piston; a temperature
monitor connected to said controller, said temperature monitor
monitoring a temperature of said frozen product contained within
said product container; a product determination device connected to
said controller, said determination device determining a
formulation of said frozen product contained with said product
container; a force sensor connected to said controller, said force
sensor measuring said force applied to said first end of said
product container; and a dispensing valve connected to said spout,
said dispensing valve regulating a flow of said frozen product
dispensed from said spout, said controller adjusting said force
applied to said piston based on said temperature of said frozen
product and said formulation of said frozen product, said force
being adjusted such that frozen product is dispensed from said
dispensing spout until said desired portion has been dispensed.
24. The apparatus, as claimed in claim 23, wherein said frozen
product is maintained at a constant temperature.
25. The apparatus, as claimed in claim 23, wherein said force
applied to said piston is maintained substantially constant during
dispensing of said frozen product from said dispensing spout.
26. The apparatus, as claimed in claim 23, further comprising: a
product volume sensor connected to said controller, said product
volume sensor determining when said product container is empty of
said frozen product.
27. The apparatus, as claimed in claim 23, further comprising: an
actuator connected to said controller and said dispensing valve,
said actuator receiving instructions from said controller and
moving said dispensing valve in response to said instructions.
28. The apparatus, as claimed in claim 23, further comprising: a
position monitor connected to said controller, said position
monitor monitoring a linear position of said piston as said piston
moves within said product container, said controller adjusting said
force applied to said piston based on said linear position of said
piston in said product container.
29. A dispensing system for dispensing frozen product, said
dispensing system comprising: a product container positioned within
said dispensing system, said product container holding said frozen
product; a label attached to said product container, said label
identifying a formulation of said frozen product contained in said
product container; a controller connected to said dispensing
system; a reader connected to said controller, said reader reading
said label and determining said formulation of said frozen product
contained in said product container; and a drive connected to said
controller, said drive applying a force to said container, said
force being adjusted by said controller based on at least said
formulation of said frozen product such that said frozen product is
dispensed from said container at a uniform rate.
30. A container for holding frozen product, said container
comprising: (a) an spout; (b) an interior volume connected to said
spout, said interior volume housing said frozen product; and (c)
data media connected to said container and positioned in a
predetermined area on an exterior of said container, wherein said
data media provides information to dispense said frozen product at
a uniform rate from said spout.
31. A method for dispensing a desired amount of frozen product from
a product container, said method comprising the steps of: providing
information on said product container, said information relating to
said frozen product contained within said product container;
reading said information on said product container; determining
said desired amount of frozen product to be dispensed from said
product container; determining a force based on said information
for dispensing the frozen product at a uniform rate; determining an
application time to apply said force to said product container to
dispense said desired amount of frozen product based on said
uniform rate of dispensing; applying said predetermined force to
said product container for said application time; and dispensing
said desired amount of frozen product from said product
container.
32. An apparatus for dispensing frozen product, said apparatus
comprising: (a) a product container containing said frozen product,
said product container including: a piston movably positioned
within an interior portion of said product container; and a spout
connected to said product container; (b) a drive mechanism that
abuts said piston, said drive mechanism applying a force to move
said piston and compress said frozen product within said product
container, said movement extruding said frozen product from said
spout wherein said product container is sufficiently rigid such
that said product container is not deformed by movement of said
piston and said product container is sufficiently deformable such
that said product container is collapsible when said product
container is empty of frozen product.
33. A method for dispensing a desired amount of frozen product from
a product container having a piston movably positioned within said
product container and a dispensing valve connected to said product
container, said method comprising the steps of: providing
information on said product container, said information relating to
said frozen product contained within said product container;
reading said information on said product container; determining a
pre-load force value based on said information from dispensing said
frozen product at a uniform rate; applying said predetermined
pre-load force to said piston in said product container;
determining a desired portion of frozen product to be dispensed
from said product container; determining an additional force to
dispense said desired portion, said additional force is in addition
to said pre-load force; monitoring a position of said piston as
said frozen product is dispensed from said product container;
opening said dispensing valve; applying said additional force to
said piston; varying said additional force based upon said position
of said piston; dispensing said frozen product from said product
container through said dispensing valve; and closing said
dispensing valve when said desired portion has been dispensed.
34. The method as claimed in claim 33, wherein said step of reading
information provides maximum and minimum force for application to
said piston.
35. The method as claimed in claim 34, wherein said step of varying
said additional force varies said additional force such that said
pre-load force in addition to said additional force range between
said maximum and minimum force.
36. The method as claimed in claim 34, further comprising the steps
of: monitoring a temperature of said frozen product; increasing
said temperature of said frozen product when said applied force is
greater than said maximum force, and decreasing said temperature of
said frozen product when said applied force is less than said
minimum force.
37. The method as claimed in claim 34, further comprising the step
of: reducing said pre-load force applied to said piston.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an apparatus and method for
dispensing a frozen product, and more particularly, for an
apparatus and method using a product container having a control
valve that dispenses the frozen product in a desired shape at a
uniform rate and quantity.
[0003] 2. Statement of the Problem
[0004] A wide variety of dispensing systems are used to dispense
frozen product (such as, ice cream and/or frozen yogurt). In one
conventional configuration, as shown in U.S. Pat. No. 5,417,355,
the frozen product is housed within a product container, typically
a cardboard container having a cylindrical shape. A drive motor or
source of high pressure air moves a piston to apply a drive force.
The force causes the piston to directly contact a portion of the
container (i.e., a lid) or the frozen product itself such that
frozen product is pushed through the container and out a spout in
the dispensing system. In another conventional configuration, the
dispensing system uses a deformable container that contains the
frozen product. The deformable container also includes a spout, and
the deformable container can have an "accordion-like" structure (as
shown in U.S. Pat. No. 5,505,336) or a flexible bag structure (as
shown in U.S. Pat. Nos. 5,463,878, 5,265,764 and 5,421,484). In
this configuration, the drive force causes the piston to directly
contact the deformable container to extrude the frozen product from
the spout. In yet another conventional configuration, as shown in
U.S. Pat. No. 5,385,464, the dispensing system uses a product
container to house the frozen product. An automated system is used
to scoop and dispense the frozen product from the container. In all
of these conventional systems, the frozen product is not dispensed
at a uniform rate primarily due to the formulation and temperature
of the frozen product that is dispensed. Hence, the frozen product
is dispensed at varying rates and, as such it is difficult for an
operator of the dispensing system to easily dispense a specifically
desired amount of the frozen product. Therefore, a need exists to
provide a system that dispenses frozen product at a uniform rate
regardless of the formulation.
[0005] Further, since these conventional systems do not dispense
the frozen product at a uniform rate, the dispensing of a specific
portion is difficult. The portion control is difficult because the
flow rate typically varies according to the formulation, viscosity,
temperature, quality and the consistency of the frozen product. In
addition, adding to this difficulty is the compressibility of the
frozen product which can be up to about 50% air by volume. In most
conventional dispensing systems, there is no portion control. The
portion is dispensed by an operator using eyesight control, and the
operator of the system cannot consistently gauge the amount of
frozen product being dispensed from the system over any given time
because the formulation and the temperature of the frozen product
periodically change. Therefore, the operator can easily dispense a
larger or smaller amount of the frozen product than is desired by
the customer. Dispensing a higher amount affects profitability of
the system, and dispensing a lower amount causes customer
dissatisfaction. Requiring the operator to weigh the frozen product
that has been dispensed is not practical in the fast food
environment. Such weighing of the frozen product is expensive
especially in a high volume commercial operation. Further, while
weighing protects the customer from receiving a shortage, it does
not protect the operator when too much is dispensed. In addition,
as shown in U.S. Pat. No. 5,464,120, some conventional systems that
offer portion control include a metering chamber that is the size
of the desired portion and is attached to the spout of the
container. The frozen product is extruded into the metering chamber
and once the metering chamber is filled, the frozen product is
dispensed to the customer. In these systems, the metering chamber
must be cleaned and sanitized especially when a different flavor is
inserted into the dispensing system. Further, the size of the
dispensed portion is dependent upon the size of the metering
chamber, and therefore, variable sized portions cannot be dispensed
from the dispensing system. As such, a need exists for a system
that reliably dispenses a portion that has been purchased by the
customer or allows an operator to easily gauge the amount of frozen
product that has been dispensed, and such a system should dispense
the frozen product at a uniform rate regardless of the formulation
of the frozen product and without using additional metering
chambers.
[0006] Some conventional frozen product dispensing systems, such as
the cardboard and deformable container configurations, use a rigid
cylindrical support (such as shown in U.S. Pat. Nos. 5,463,878,
5,265,764 and 5,421,484). The forces required to extrude frozen
product are large and the sidewalls of such containers are not
strong enough to withstand such forces. The cylindrical support
provides significant sidewall support during dispensing the frozen
product. In these embodiments, the cardboard or flexible container
is positioned within the cylindrical support. A piston slidably
engages the cylindrical support container and the drive force
provided by the motor drive or high pressure air source forces the
piston to extrude the frozen product from the container. The use of
such a support is expensive and a need exists to eliminate the use
of such a support by providing a frozen product container having
sufficient sidewall strength to withstand the drive forces.
[0007] When the frozen product container is housed within the
cylindrical support, it is difficult to determine when the frozen
product container is empty. As such, there are times when the
frozen product container is replaced before it is empty of frozen
product, and thus, frozen product is wasted. Therefore, a need
exists for a system that detects when a product container is
empty.
[0008] In some conventional frozen product dispensing systems, caps
and valves are connected to the spout on the frozen product
container to perform particular tasks. For example, a stopper cap
is connected to the spout after the container is filled with
product during a fill procedure. The stopper cap seals the product
in the container after the filling procedure and during freezing
and transportation of the container. When the container is loaded
into a dispensing system, the stopper cap is removed from the spout
and discarded. A dispensing valve is then attached to the spout.
The dispensing valve allows frozen product to be dispensed from the
spout when force is applied to the container by the plunger.
Typically, the dispensing valve is an integral part of the
dispensing system and is used for each container that is placed in
the dispensing system. This use of the dispensing valve presents
sanitary problems if the dispensing valve is not properly cleaned
when new frozen product containers are added. Further, when the
frozen product contains chunks of fruit, nuts, chocolate or other
ingredients, the dispensing valve can become clogged. As a result,
the dispensing spout is frequently removed and cleaned adding to
the costs of the dispensing operation. Thus, a need exists for a
single valve as part of the frozen product container that seals the
container after filling, dispenses the frozen product, and is
thrown away with the empty container.
[0009] Therefore, a need exists for a frozen product dispensing
system that dispenses the frozen product at a uniform rate
regardless of the formulation of the frozen product. A need exists
for a dispensing system that can dispense a specified portion
purchased by a customer. In addition, a need exists for a frozen
product container that has sufficient sidewalls strength to
withstand forces required to extrude the frozen product from the
dispensing system. A need also exists for a container that is
collapsible after use to minimize the volume of refuse. Further, a
need exits for a dispensing system that detects when the frozen
product container is empty. Also, a need exists for a single
dispensing valve that is installed to seal the container after
filling and is also used as the dispensing spout during dispensing
the frozen product. In addition, a need exists for a single
dispensing valve that eliminates costs associated with disassembly
and sanitation.
SUMMARY OF THE INVENTION
[0010] 1. Solution to the Problem
[0011] The present invention solves the problems mentioned above
and other problems associated with dispensing frozen product. The
present invention includes a dispensing system that dispenses
frozen product at a uniform rate regardless of, at least, the
formulation, percent by volume of air, quality of the frozen
product and temperature of the frozen product. The present
invention includes a dispensing system that dispenses a specified
portion purchased by a customer. The present invention provides a
dispensing system that uses a product container that collapses when
empty, and yet has sufficient sidewall support to withstand
dispensing without external support around the container. Further,
the present invention provides a dispensing system that detects
when the frozen product container is empty. In addition, the
present invention also provides a single dispensing valve in the
container that can be attached to the product container before or
after filling, and the dispensing valve can used for filling and
for dispensing the frozen product so as to eliminate cleaning of
conventional spouts that are part of the dispensing system.
[0012] 2. Summary
[0013] The present invention includes a frozen product dispensing
system for dispensing a desired portion of frozen product. The
dispensing system includes a product container positioned within
the dispensing system and containing the frozen product. The
product container also includes a spout. A single dispensing valve
is connected to the spout before or after the product container is
filled with frozen product to seal the frozen product in the
product container, and the dispensing valve is also used to control
dispensing of the frozen product from the product container.
[0014] A label or other identifier is attached to the product
container identifying the formulation of the frozen product
contained within the product container. A controller is provided in
the dispensing system. A reader is connected to the controller and
reads the label. The reader allows the controller to determine
and/or display the formulation and other information relating to
the frozen product contained within the product container. A drive
is connected to the controller, and the drive applies force to the
product container. The controller uses various techniques to
dispense the frozen product from the product container at a uniform
rate. Further, the controller also uses these techniques to
dispense a desired portion from the dispensing system.
[0015] In addition, the product container has sufficient sidewall
strength such that the product container is not deformed when the
force applied to dispense the frozen product from the spout. Yet,
the product container is also sufficiently deformable that the
product container is collapsible when it is empty of frozen
product. Further, a product volume sensor is provided and is
connected to the controller. The product volume sensor determines
when the product container is empty of frozen product. In addition,
the product volume sensor can supply volume information to the
controller such that the volume of frozen product in the product
container is displayed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is an illustration showing the major components of an
embodiment of the frozen product dispensing system of the present
invention;
[0017] FIG. 1a is a perspective view illustrating a product
identification label used in the present invention;
[0018] FIG. 2 is a cross-sectional view of the frozen product
container of the present invention;
[0019] FIG. 2a is a cross-sectional view of the retaining ring used
in the present invention;
[0020] FIG. 2b is an illustration showing the product container at
various stages of use in the present invention;
[0021] FIG. 2c is a cross-sectional cut-away view of the piston
used in the present invention;
[0022] FIG. 3 is a cross-sectional view of an dispensing valve of
the present invention in an open position;
[0023] FIG. 4 is a cross-sectional view of a closed dispensing
valve of the present invention in a closed position;
[0024] FIG. 5 is a perspective view of a dispensing valve of the
present invention in an open position;
[0025] FIG. 6 is a perspective view of a dispensing valve of the
present invention in a closed position;
[0026] FIG. 7 is a perspective view of another embodiment of a
dispensing valve of the present invention;
[0027] FIG. 8 is a perspective view of yet another embodiment of a
dispensing valve of the present invention in an open position;
[0028] FIG. 9 is a perspective view of yet another embodiment of a
dispensing valve of the present invention in a closed position;
[0029] FIG. 10 is a perspective view of even another embodiment of
a dispensing valve of the present invention in a open position;
[0030] FIG. 11 is a perspective view of even another embodiment of
a dispensing valve of the present invention in an closed
position;
[0031] FIG. 12 is a cross-sectional view of another embodiment of a
dispensing valve of the present invention in an closed
position;
[0032] FIG. 13 is a perspective view of another embodiment of a
dispensing valve of the present invention in a open position;
[0033] FIG. 14 is a flow chart showing one embodiment of a method
for dispensing frozen product of the present invention;
[0034] FIG. 15 is a flow chart showing another embodiment of a
method for dispensing frozen product of the present invention;
and
[0035] FIG. 16 is a flow chart showing another embodiment of a
method for dispensing frozen product of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0036] 1. Overview
[0037] In FIG. 1, a frozen product dispensing system 100 is
illustrated. The dispensing system 100 is used to dispense frozen
product 132 such as, for example, ice cream, frozen yogurt or any
other frozen confectionery product or dessert that is dispensed for
consumption from a product container 120 into a server 134, such as
a cup. In one embodiment, a customer purchases a desired amount of
frozen product 132 and an operator uses the dispensing system 100
to dispense the desired amount. The frozen product 132 is dispensed
from the dispensing system 100 at a uniform rate by adjusting the
force (F) applied to piston 126 after monitoring a variety of
parameters associated with the frozen product 132.
[0038] In another embodiment, the dispensing system 100
automatically dispenses the frozen product 132. In this embodiment,
a customer purchases a desired amount of frozen product by
inserting a predetermined amount of money into the dispensing
system 100. A force is applied to the piston 126. The force is
monitored and adjusted according to various parameters associated
with the frozen product 132. In particular, the force is applied
for a specified period of time to dispense the desired amount. In
addition, the linear displacement of the piston 126 is measured to
determine the amount of frozen product 132 dispensed from the
product container 120. The dispensing system 100 then automatically
dispenses at a uniform rate the desired amount of frozen product
132 to the customer.
[0039] The present invention, generally, dispenses frozen product
132 at a uniform rate from dispensing system 100. The present
invention provides an apparatus and associated method for
dispensing a specified desired portion of frozen product 132 via a
product container 120 that requires no sidewall 121 and 123
support. In addition, the dispensing system 100 monitors a variety
of parameters such that the volume of the product container 120 is
determined. Further, the present invention also overcomes the
aforementioned problems associated with other systems that have
been used in the art.
[0040] 2. Dispensing System
[0041] In FIG. 1, the dispensing system 100 includes a product
container 120 having a spout 130. The product container 120
contains frozen product 132, and resides in housing 102.
Additionally, the product container 120 engages a retaining ring
122 that is releasably attached to support 104 that is connected to
the housing 102. The retaining ring 122 and the support 104 ensure
that the product container 120 is positioned in a vertical
dispensing orientation, as shown in FIG. 1. In this position, the
spout 130 extends from the housing 102. A dispensing valve 320 is
connected to the spout 130 to regulate the flow of the frozen
product 132. The server 134 is placed below the spout 130 and
dispensing valve 320 during dispensing the frozen product 132. The
server 134 can be automatically placed below the spout 130 and
dispensing valve 320 by the system 100 or an operator can manually
place the server 134 below the spout 130 and dispensing valve 320.
The product container 120 is removable from the housing 102. For
example, when the product container 120 is empty of frozen product
132, the product container 120 can be removed and replaced by a new
container (not shown) in the dispensing configuration shown in FIG.
1. The positioning of the product container 120 is aided by a
retaining ring 122 that is connected to the product container 120.
The retaining ring 122 is releasably held in place by the support
104 using a complementary fitting arrangement as described
below.
[0042] In FIG. 1, all the components used to dispense the frozen
product 132, in a first embodiment, are contained within the
housing 102. However, it should be appreciated that particular
components, such as the controller 150 and the motor drive 144, in
a second embodiment, could optionally be housed outside the housing
102. Also, in another embodiment, the refrigeration housing 102 can
house a plurality of product containers 120. In FIG. 1, the
dispensing system 100 of the present invention is illustrated and
does not represent any one of the numerous conventional designs for
providing a refrigeration housing 102 around the product container
120.
[0043] Further, the housing 102 typically encloses the product
container 120 and maintains the product container 120 at a constant
temperature. As such, the housing 102 can, essentially, be a
refrigerator having a refrigerant (not shown), a compressor (not
shown) and a temperature control system (not shown) to maintain a
constant temperature environment inside housing 102. However, the
present invention should not be interpreted as being limited by the
refrigeration mechanisms described herein, and the present
invention should encompass other refrigeration mechanisms known in
the art. In one embodiment, the temperature inside the housing 102
is controlled by the controller 150 such that the frozen product
132 is maintained at a constant temperature ranging from about 15
to 20.degree. F. It should be understood that, in one embodiment,
the controller 150 can adjust the temperature inside the housing
102 because the controller is connected to the temperature control
system (not shown) of the housing 102. In addition, the temperature
control system (not shown) can include fans (not shown) and defrost
components (not shown.
[0044] Also shown in FIG. 1, the dispensing system 100 includes a
plunger 140 that is connected to a motor drive 144 via shaft 142.
IN one embodiment, the motor drive 144 is electrically powered and
mechanically driven. In another embodiment, the motor drive 144
comprises a source of highly pressured air. The plunger 140 abuts
piston 126 that is positioned in the product container 120, and in
the embodiment shown in FIG. 1, the piston 140 contacts a force
distribution disk 128 such that any force that is applied to the
piston 126 is equally distributed about the full area of the piston
126.
[0045] In FIGS. 1 and 2, the plunger 140 is shown being smaller
than the piston 126, therefore, requiring a force distribution disk
128. In this embodiment, the plunger 140 has a formed end 141, and
the force distribution disk 128 has a formed cavity 129. Thus, when
the formed end 141 is positioned within the formed cavity 129 a
positive seat is formed that allows the force (F) to be applied
about the entire area of the piston 126, Additionally, in this
embodiment, the force distribution disk 128 is placed between the
piston 126 and the plunger 140. However, it should also be
appreciated that the plunger 140 can optionally have a different
configuration or shape such that the force applied by the drive
motor 144 is equally distributed about the perimeter of the piston
126. In one embodiment, the plunger 140 is configured to be
approximately the same size as the piston 126. In this
configuration, the plunger 140 exerts force around the entire area
of the piston 126 and the force distribution disk 128 is not
required. In another embodiment, the plunger 140 has a tapered
configuration wherein the end connected to the shaft 142 is
approximately the size of shaft 142 and the end that contacts the
piston 126 is approximately the same size as the piston 126. Again,
in this embodiment, the plunger 140 is capable of exerting a force
around the entire area of the piston 126 and the force distribution
disk 128 is not required. It should be appreciated that the present
invention is not limited as to the size or the shape of the plunger
140, how the plunger 140 engages the piston 126, and whether or not
a force distribution disk 128 is used.
[0046] The dispensing system 100 also includes a controller 150
that is used to control the dispensing of the frozen product 132.
It should be noted that the controller 150 is not, typically,
located in the housing 102. Typically, the wires 152, 154, 156, 157
and 158 enter the housing 102 while the controller 150 is located
outside housing 102. The controller 150 is typically a
microprocessor-based computer having an associated memory. The
controller 150 can execute programs that involve dispensing the
frozen product, and the controller 150 can monitor input parameters
and adjust output parameters accordingly, as will be discussed
subsequently. The controller 150 can be any commercially-available
device or a device specially designed for this application that
performs the function described above and other functions.
[0047] a. Temperature
[0048] The controller 150 is connected to a temperature sensor 162
via line 158. The temperature sensor 162 monitors the temperature
of the frozen product 132 in the product container 120. For
example, the temperature sensor 162 can comprise a thermistor or a
thermocouple that provide a resistance or a voltage signal,
respectively, to the controller 150 in response to the temperature.
Accordingly, the temperature sensor 162 is commercially-available
temperature measuring device that proves an output signal that can
be read or interpreted by the controller 150. The temperature of
the frozen product 132 is measured by placing the temperature
sensor proximate to or touching the product container 120. Since
the housing 102 is maintained in a constant temperature and the
frozen product 132 is tempered, this proximate location gives an
accurate reading of the temperature of the frozen product 132
without actually having the temperature sensor 162 directly contact
the frozen product.
[0049] b. Information on Container
[0050] The controller is also connected to a reader 160 through
line 156. The reader 160 identifies information about the frozen
product 132 on label 170. The label 170 is sensed by the reader 160
provides information to the controller 150 that, in part, allows
the dispensing system 100 to dispense frozen product 132 at a
uniform rate regardless of the formulation of the frozen
product.
[0051] In one embodiment, as shown in FIG. 1a, the information is
contained on label 170 attached to the product container 120 in a
predetermined area 175. When the product container 120 is installed
in the dispensing system 100, the product container 120 is oriented
as indicated by arrows 174 such that the reader 160 senses the
label 170. In FIG. 1(a), the label 170 is shown attached to piston
126 in predetermined area 175. In another embodiment, the label 170
is attached to a non-moving portion of the product container 120,
such as, for example, a sidewall 121 or 123. In another embodiment,
the label 170 is attached to a tag (no shown) that is connected to
the product container 120.
[0052] The information from the label 170 is read by the reader 160
and supplied to the controller via line 156. The information
contained in label 170 can comprise any suitable information
including the formulation of the frozen product 132. Once the
controller 150 receives the information on the label 170, it
correlates that information to parameters stored in memory in
controller 150 in order to dispense the frozen product 132 at a
uniform rate. The parameters adjusted by the controller 150 can
include the force (F) applied to the piston 126 and/or the
compressibility of the frozen product 132. In one embodiment, the
information contained in the label 170 includes an indicator that
correlates to the parameters stored in associated memory. The
parameters corresponding to the information on label 170 are then
used to dispense the frozen product 132 at a uniform rate. In
another embodiment, the label 170 comprises a force value and/or a
rate of linear displacement of the piston 126 that is associated
with a dispense rate that is used to dispense the frozen product
132 at a uniform rate. In one aspect of this embodiment, no
correlation in memory occurs. In even another embodiment, the
information on label 170 comprises or correlates to a maximum and
minimum force that can be applied to the piston 126. In yet another
embodiment, the information contained in the label 170 includes
product information that is supplied to a display sign 172 through
the controller 150 via line 173. The product information is
displayed to customers through the display sign 172 that is
attached to the housing 102. The product information includes the
formulation (such as, chocolate fudge) which is displayed on the
display sign 172.
[0053] The reader 160 is a device that obtains information from the
label 170. In one embodiment, the reader 160 comprises a bar code
reader that reads a barcode label 170 that is attached to or is
supplied with the product container 120 in area 172. In another
embodiment, the reader 160 comprises a radio-frequency reader and
the label 170 comprises a passive or active radio-frequency
transducer or tag. In one aspect of this embodiment, the
radio-frequency transducer provides the information to the
radio-frequency reader 160 when the radio-frequency transducer is
placed proximately to the radio-frequency monitor, such as during
installation of the product container 120. It is to be expressly
understood that any conventional data media 170 such as, for
example, magnetic data storage tape attached to the container 120
and positioned in predetermined area 172 could be used wherein a
suitable reader 160 conveys information concerning the frozen
product 132 to the controller 150. The information could be in any
suitable data format and could include any of the following: the
product formulation, the product identity, a constant value, a
force value, etc.
[0054] C. Force Sensor
[0055] As shown in FIGS. 1 and 2, the controller 150 is also
connected via line 152 to the motor drive 144 and by line 154 to a
force sensor 164. As such, the controller 150 monitors the force
(F) over line 154 applied to the piston 126 by the motor drive 144
and adjusts the force as discussed above. It should be noted that
in another embodiment the force sensor 164 is an integral component
of the motor drive 144, and thus the line 154 is eliminated. As
explained above, the motor drive 144 can comprise an electric
motor, such as a stepper motor, that is controllable by controller
150. It should also be appreciated that the motor drive 144 can
comprise any commercially-available drive mechanism that can be
controlled by controller 150. In FIG. 1, the force sensor 164 and
motor drive 144 are located within the housing 102. However, in a
preferred embodiment, the motor drive 144 including the integral
force sensor 164 are located outside the housing 102 so that the
refrigeration in the housing 102 does not cause errors in the force
measurement due to temperature variations.
[0056] Further, the force sensor 164 can comprise a force-sensitive
metallic sensor such as, for example, a strain gauge or any other
commercially-available force sensor. In addition, it should also be
appreciated that the force sensor 164, as shown in FIGS. 1 and 2,
is positioned between the force distribution disk 128 and the
piston 126. However, the force sensor 164 can optionally be
positioned between the plunger 140 and the force distribution disk
128. In another embodiment, the force sensor 164 is attached to the
plunger 140. In even another embodiment, the force sensor 164 is
included as an integral component within the drive motor 144. When
using the force distribution disk 128, the force sensor 164 can be
optionally placed between the force distribution disk 128 and the
piston 126 (as shown in FIGS. 1 and 2), or the force sensor 164 can
be placed between the plunger 140 and the force distribution disk
128. In the latter configuration, the force sensor 164 can
optionally be attached to the formed end 141 of the plunger 140.
When a force distribution disk 128 is not used, the force sensor
164 is placed between the plunger 140 and the piston 126, and the
force sensor 164 can optionally be attached to the plunger 140. Any
number of conventional approaches could be used to measure the
force actually being applied by the plunger 140 so that the system
is assured that the correct force (F) as determined by the
information in label 170 is delivered.
[0057] d. Product Container Position
[0058] As shown in FIGS. 1 and 2, in dispensing the frozen product
132, the product container 120 is positioned within the housing 102
in a dispensing orientation that has the retaining ring 122
securely fixed to support 104. The retaining ring 122 is secured to
support 104 connected to housing 102 such that the piston 126 can
move within the product container 120 while the sidewalls 121 and
123 of the product container 120 do not move. As shown in FIG. 2a,
the retaining ring 122 is connected to the second end 220 of the
product container 120. The retaining ring 122 includes a retaining
ring tongue 230 and a retaining ring groove 234. The support 104
has a complementary-type fitting that includes a fixed support
groove 232 and a fixed support tongue 236. When the product
container 120 is placed in the housing 102, the retaining ring
tongue 230 is releasably positioned in the fixed support groove 232
and the fixed support tongue 236 is positioned in the retaining
ring groove 234. This complementary connection allows the product
container 120 to receive the plunger 140 and the force (F) that is
applied to the piston 126 without collapsing the product container
120 during extrusion as will be subsequently explained. In one
embodiment, the retaining ring 122 is composed of, for example,
thermoplastic, nylon or polypropylene or any other suitable
polymeric material.
[0059] It should be noted that the embodiment shown in FIGS. 1, 2
and 2a represent one mechanism used to secure the product container
120 in the dispensing position. However, it should be appreciated
that the present invention is not limited to the embodiment shown
and should encompass any mechanism know or used in the art for
maintaining the product container 120 in a dispensing position.
[0060] d. Dispensing Frozen Product
[0061] The spout 130 is in an opposite position from the piston
126, and the spout 130 extends from the interior of housing 102 to
the exterior. In addition, as the motor drive 144 moves the plunger
140 to apply force (F) to the piston 126, the piston 126 moves
toward the spout 130 and compresses (C), as shown in FIG. 1, the
frozen product 132 within the product container 120. It should be
noted that the frozen product 132 can be compressed by about 35 to
40% without frozen product 132 being extruded from the spout 130.
This compression of the frozen product 132 is caused in part
because the frozen product contains high amounts of air within the
frozen product 132. Once the air has been compressed, any further
force applied to the plunger 140 will cause frozen product 132 to
be extruded from the spout 130 into the server 134.
[0062] It should also be noted that the amount of compression (C)
of the frozen product 132 before extrusion is dependent upon the
formulation of the frozen product 132. In addition, the
compressibility (C) of the frozen product 132 can cause a time lag
between the time that the force (F) is applied and when the frozen
product 132 is dispensed through the spout 130. Therefore, once the
formulation of the frozen product and/or other associated
information is input to the controller 150, the controller 150
determines the correct force (F) that must be applied to the piston
126 based on the input information. In one embodiment, this force
(F) can be used to pre-load the frozen product 132 so as to
eliminate any air located in the frozen product 132 and the time
lag associated with compressibility (C) of the frozen product
132.
[0063] In addition, to dispense the frozen product 132 the
controller 150 instructs the drive motor 144 to apply the a
required force above and beyond the pre-load force (F) for the
required amount of time and/or the required linear displacement of
the piston 126 based on the programmed information such that the
frozen product 132 is dispensed from the spout 130. Also, in
another embodiment, the controller 150 instructs the drive motor
144 to apply the required force (F) to dispense the frozen product
132 at a uniform rate and an operator dispenses a desired portion
of the frozen product 132. After a period of inactivity, the
controller 150 can reduce the pre-load force (F) to prevent loss,
run-off or phase transformation of the frozen product 132. The
pre-load force (F) and the amount of reduction can be included in
the information on the label 170 or correlated with the information
on the label 170. In addition, the reduction of the pre-load force
(F) can be independent of the information contained in the label
170. As mentioned previously, the dispensing system 100 can have
maximum and minimum force limits that can be correlated to the
information in label 170 or be independent of the information
contained on the label 170.
[0064] In another aspect of the present invention, if the force (F)
applied to the piston 126 is higher or lower than the maximum and
minimum force limits, the dispensing system 100 via the controller
150 can increase or decrease, respectively, the temperature in the
housing 102 such that the force (F) that is applied to the piston
126 is within these limits. As mentioned, it should also be
appreciated that these maximum and minimum force limits can be
associated with the formulation of the frozen product 132 and/or
information contained in the label 170.
[0065] Generally, the controller 150 continuously monitors the
inputs of the temperature sensor 162, the reader 160, the force (F)
applied to the piston 126 and the linear displacement of the piston
126 to adjust the force (F) that is to be applied to the piston 126
by the drive motor 144 such that the frozen product 132 is
dispensed at a uniform rate. Further, the controller 150 monitors
the applied force (F) that is supplied to the piston 126 via a
force sensor 164. Based on the applied force, temperature,
formulation, linear displacement of the piston 126 and other
properties of the frozen product 132, the controller 150 instructs
the motor drive 144 to adjust the force (F) applied to the piston
126 through the plunger 140. The force (F) is applied such that the
frozen product 132 is extruded from the spout 130, and the
controller 150 adjusts the force (F) based on the temperature,
formulation, force, linear displacement of the piston 126 and other
factors such that the frozen product 132 is extruded at a uniform
rate from the spout 130.
[0066] f. Portion Control
[0067] In one embodiment, the controller 150 can also determine the
desired amount of frozen product 132 that is to be dispensed from
an input by the operator or the customer. In determining the
portion size, a plurality of switches, touch pad or other suitable
input devices 101 corresponding to various portion sizes such as,
for example, small medium and large, can be connected to the
controller 150 and optionally located on the housing 102. The input
device 101 is shown in FIG. 1 attached to the housing 102. However,
it should be appreciated that the input device 101, in another
embodiment, can be located externally from the housing 102. The
input device 101 via line 103 triggers an instruction set in the
controller 150 to dispense a specified amount of frozen product
132. The instruction set can include, for example, pre-loading the
piston 126 with a force (F); mechanically opening dispensing valve
320 using actuator 155; monitoring the movement and/or linear
position of the piston 126 using position sensor 125 until the
desired amount is dispensed; and mechanically closing the
dispensing valve 320.
[0068] It should be noted that, in another embodiment, the time
that the dispensing valve 320 is open is measured rather than the
position of the piston 126. In this embodiment, the controller 150
determines the amount of force (F) to be applied to the piston 126
over the predetermined amount of time based on a uniform flow rate.
In a preferred embodiment, the controller 150 determines the amount
of force to apply to the piston 126 which can be above and beyond
the pre-load force (F). This added force can be applied until the
piston is linearly displaced a predetermined amount or the
dispensing valve 320 has been open for a predetermined amount of
time. Therefore, once the desired amount is determined, the
dispensing system 100 dispenses the amount of frozen product 132
that is desired by applying the force for a predetermined amount of
time or until the piston 126 has moved a predetermined linear
distance. As such, the system 100 controllably dispenses the
desired amount of frozen product 132.
[0069] In the present invention, a feedback loop 151 can be used to
adjust the force (F) applied to the piston 126 such that the
product is continuously dispensed at a uniform rate. As shown in
FIG. 1, the feedback loop 151 is part of the controller 150. The
feedback loop 151 has control inputs from, at least, the position
sensor 125, the motor drive 144, the force sensor 164, the reader
160, the temperature sensor 162 and the actuator 155. In another
embodiment, the feedback loop 151 is located externally from the
controller 150. It should be appreciated that the feedback loop 151
can have more or less control inputs, and the present invention
should not be interpreted as being limited by the number and/or
type of control inputs and the location of the feedback loop
151.
[0070] In one embodiment, the feedback loop 151 comprises a
proportional integral differential (PID) feedback loop implemented
by the controller 150 that varies the force (F). In this
embodiment, the force (F) applied to the piston 126 can be varied
by the controller 150 according to the PID feedback loop 151 using
the position of the piston 126 measured by the position sensor 125
as a control signal. In another embodiment, using a PID feedback
loop 151 implemented by the controller 150, the force (F) can be
held constant while the signal from the force sensor 154 is used as
the control signal in the PID feedback loop 151. The control of the
linear drive rate of the plunger 140 in conjunction with the
control signals mentioned above allow the frozen product 132 to be
dispensed at a constant rate. It should be noted that these control
loops may require that the piston 126 be pre-loaded with a force
(F) such that the air is compressed from the frozen product 132 and
the time lag reduced between application of the force and
dispensing the frozen product.
[0071] It should also be appreciated that in another embodiment the
dispensing system 100 can also be manually operated wherein an
operator dispenses the desired amount of frozen product 132. In
this aspect of the invention, the operator can easily gauge the
amount of frozen product 132 that is dispensed because the frozen
product 132 is dispensed at a uniform rate regardless of the
formulation of the frozen product 132.
[0072] g. Product Container
[0073] As shown in FIG. 2, the product container 120 includes a
retaining ring 122, a piston 126 and a spout 130. The product
container 120 is used to contain the frozen product 132. In one
embodiment, the product container 120 is composed of a
high-strength semi-rigid plastic container, such as, for example, a
film laminate that is cylindrical in shape. A first end 210 of the
product container 120 is connected to the spout 130. The product
container 120 is formed during manufacturing to include the spout
130. As a result, the spout 130 is integrally formed as part of the
product container 120 during manufacturing. The second end 220 of
the product container 120 is connected to a retaining ring 122 that
is secured to support 104. In one embodiment, the retaining ring
122 is plastic and is heat welded to the second end 220 of the
product container 120.
[0074] In addition, the product container 120 is preferably
positioned such that the first end 210 is opposite from the second
end 220 in a vertical orientation such that the sidewalls 121 and
123 are positioned below the retaining ring 122. The sidewalls 121
and 123 do not have external support.
[0075] As shown in FIG. 1, the second end 220 of the product
container 120 contains a piston 126 that moves within the product
container 120 as a plunger 140 contacts and applies force (F) to
the force distribution disk 128. The piston 126 is an integral part
of the product container 120 and serves several functions. The
piston 126 is used to compress the frozen product 132 within the
product container 120. The piston 126 is also used to seal the
second end 220 of the product container 120 during the filling
procedure. In one embodiment, the piston 126 is circular and is
composed of a hardened plastic material that is able to withstand
the force applied to the plunger 140.
[0076] Since there is no external support, the sidewalls 121 and
123 can slightly bulge 190 around the raised annular edge 124 when
force (F) is applied to the piston 126 as shown in FIG. 2c.
However, since the product container 120 is not compressed when
force is applied to the piston 126 (i.e., only the frozen product
132 is compressed), the frozen product 132 is dispensed from the
spout 130 of the product container 120. Further, it should be noted
that the thickness of the sidewalls 121 and 123 of the product
container 120 are chosen such that only bulging 190 occurs in the
sidewalls 121 and 123 during dispensing of the frozen product 132
is prevented. In one embodiment, the sidewalls 121 and 123 have a
thickness ranging from about 3 to 10 mils. As a result of the
thickness of sidewalls 121 and 123, the tensile strength of the
container 120 and other factors, the product container 120
maintains its shape without using exterior support for the
sidewalls 121 and 123. It should be appreciated that the present
invention should bot be interpreted as being limited by the
thickness of the sidewalls 121 and 123 of the product container
120, and the thickness values disclosed herein are presented as
examples only.
[0077] In another aspect of the present invention, as the piston
126 moves within the product container 120, the piston 126 contacts
the sidewalls 121 and 123 and the frozen product 132. As explained
above, the sidewalls 121 and 123 remain substantially vertical
during movement of the piston 126 and the frozen product 132 is
extruded from the spout 130. The piston 126, as shown in FIG. 2c,
includes a raised, slightly curved, annular edge 124 along the
circumference of the piston 126. As shown in FIG. 2C, the raised
annular edge 124 contacts the internal sides of sidewalls 121 and
123 causing bulge 190 that conforms to the shape of the raise
annular edge 124. The shape conformity of the sidewalls 121 and 123
around the raised annular edge 124 allows the piston 126 to wipe
and clean the sidewall 121 and 123 of frozen product as the piston
126 moves. Further, the raised annular edge 124 seals the piston
126 in the product container 120 so that frozen product 132 does
not squeeze out around the piston 124 as the frozen product 132 is
compressed by the force from plunger 140.
[0078] The material characteristics of the product container 120
allow it to take several shape changes from manufacture to
disposal. As shown in FIG. 2b, the product container 120 is
relatively compact after it is manufactured. When the product
container 120 is filled with frozen product 132, the container 120
expands, and once filled the dispensing valve 320 and piston 126
seals the frozen product 132 in the product container 120. It
should be noted that in FIG. 2b, the product container 120 is shown
as being filled through the dispensing valve 320. However, the
product container 120 can also be filled via the piston 126 end of
the product container 120. During this filling procedure, the
dispensing valve 320 is closed and the piston 126 is removed during
filling. After the product container 120 has been filled, the
piston 126 is placed in the product container 120.
[0079] After the product container 120 is filled, it is, typically,
deep frozen (tempered) and then shipped to a dispensing site. At
the dispensing site, the container 120 is installed in a dispensing
system 100 and the frozen product 132 is dispensed from the product
container 120. After all the frozen product 132 has been dispensed
from the product container 120, the product container 120 is again
collapsed and discarded.
[0080] h. Volume Detection
[0081] In addition, the position of the piston 126 in the
dispensing system 100 provides an indication as to the amount of
frozen product 132 that is located in the product container 120
and/or the amount of frozen product 132 that has been dispensed
from the product container 120. Further, in one embodiment, the
product container 120 has a length in the range of about 10 to 12
inches and a diameter in the range of about 6 to 8 inches and holds
about 2 to 2.5 gallons of frozen product 132. In another
embodiment, the diameter ranges from 3 to 10 inches and the length
ranges from 6 to 24 inches. Given these dimension, the vertical
position of the piston 126 corresponds to a specific amount of
frozen product 132 in the product container 120. In one embodiment
used to monitor the position of the piston 126, the controller 150
determines the distance that the shaft 142 and plunger 140 have
traveled during dispensing of the frozen product 132. From this
distance, the vertical position of the piston 126 can be determined
by the controller 150. Typically, if the motor drive 144 comprises
a stepper motor, the controller 150 can determine the position of
plunger 140 by counting the "steps" the motor drive 144 moves the
shaft 142.
[0082] In another embodiment, as shown in FIG. 1, a position sensor
125 having an array of emitters emits a number of beams 127 to
monitor the vertical position of the piston 126 and supplies this
information to the controller 150 by line 157. In this embodiment,
the position sensor 125 emits a number of beams 127 and one of the
beams 127 is reflected off the piston 126. In one embodiment, the
beams 127 are infrared signals. The position of the piston 126 is
determined by the position at which the beam 127 is reflected. From
this position, the volume of the frozen product 132 in the product
container 120 is determined. In another embodiment, the position
sensor 125 can include a single emitter at the lowest position 195
that will indicate when the product container is empty. When the
position sensor 125 senses the piston 126 at the lowest position
195, the sensor 125 will indicate that the product container 120 is
empty.
[0083] The position sensor 125 may be any commercially available
sensor that allows for the position of objects to be monitored such
as, for example, an infrared detector. The controller 150 is
capable of converting the position of the piston 126 to a volume
level of frozen product 132 in the product container 120.
Therefore, the volume of the frozen product 132 is monitored and a
signal may be sent to the operator to indicate that the product
container 120 must be replaced via, for example, an indication
light (not shown) on the housing 162.
[0084] As explained above, the linear position of the piston 126
can also indicate the amount of frozen product 132 that has been
dispensed from the product container 120. In this embodiment, the
piston is pre-loaded with a force (F) and once the dispensing valve
320 is opened, the linear displacement of the piston 320
corresponds to the amount of the frozen product 132 that has been
dispensed from the product container 120.
[0085] Further, this volume monitoring by the controller 150
ensures that the product container 120 is not prematurely replaced
and, hence, prevents the frozen product 132 from being wasted.
Further, the volume monitoring can inform the operator that the
product container 120 does not have the amount of frozen product
132 that is desired to be dispensed. In this case, the controller
150 determines the amount that is within the product container 120
and dispenses that amount. The operator is, then, informed by the
dispensing system 100 such as, for example, an indication light
(not shown) connected to the housing 102 that the product container
120 must be replaced, and after a new product container 120 is
added the remainder of the desired portion is added. It should be
noted that this procedure is only valid when the empty product
container 120 is replaced by a new product container (not shown)
having the same formulation of frozen product 132. Further, if the
dispensing system 100 is automatically operated such that an
operator or technician is not able to replace the product container
120, the customer will not be allowed to choose a product size that
is greater than the amount of frozen product 132 located in the
product container 120. Therefore, the customer is ensured to
receive the full amount of frozen product 132 that is purchased and
the product container 120 is replaced only when it is empty.
[0086] It should be appreciated that the volume monitoring
described herein should not be interpreted to limit the present
invention to the embodiments disclosed. Furthermore, the present
invention expressly encompasses other techniques known in the art
for measuring displacement of the piston 126 and the volume of
frozen product 132 in the product container 120.
[0087] i. Dispensing Valve
[0088] In FIGS. 1, 3-13, several embodiments of a dispensing valve
320 are illustrated. The dispensing valve 320 is attached to the
spout 130 of the product container 120. In one embodiment, the
dispensing valve is connected to an actuator 155 which is connected
via line 153 to the controller 150. The dispensing valve 320
provides several functions. In one function, the dispensing valve
320 is used to seal the frozen product 132 in the product container
120 before or after the product container 120 is filled with frozen
product 132, and the dispensing valve 320 also can be used to
regulate the flow of frozen product 132 during dispensing.
[0089] The dispensing valve 320 includes a valve body 322 that is
connected to the spout 130. Typically, the dispensing valve 320 is
attached to the spout 130 and is not removable. This attachment is
feasible because a single dispensing valve 320 can perform at least
two functions that were accomplished by at least two conventional
valves in conventional dispensing systems. However, it should be
appreciated that, in another embodiment, the dispensing valve 320
can be removably attached to the spout 130. The valve body 322 can
optionally have a seal 330 that is positioned between the valve
body 322 and the spout 130. The seal 330 prevents frozen product
132 from flowing between the valve body 322 and the spout 130. In
one embodiment, the seal 330 is an O-ring seal. In even another
embodiment, a fixed adhesive seal between the valve body 320 and
the spout 130 prevents any backflow of frozen product 132 between
the valve body 320 and the spout 130. In one embodiment, the fixed
adhesive seal may be provided by an epoxy or glue-type
adhesive.
[0090] The valve body 322 has a gate housing 340 that extends below
the spout end 333. The gate housing 340 accepts a movable gate 350
having a gate opening 355. As shown in FIG. 6 in one embodiment,
the gate opening 355 has a star shape. However, it should be
appreciated that the shape of the opening 355 can be any shape that
is desired such as, for example, a square, a circle, a triangle or
an octagon.
[0091] As shown in FIGS. 3 and 5, the dispensing valve 320 is
opened by moving the gate 350 in the direction of arrow A such that
the spout end 333 coaxial with the gate opening 355. In the open
position, frozen product 132 can be dispensed from the spout 130.
Further as shown in FIGS. 4 and 6, the dispensing valve 320 is
closed by moving the gate 350 in the direction of arrow B such that
the gate opening 355 is not coaxial with the spout end 333. In the
closed position, frozen product 132 is stopped from being dispensed
from the spout 130. Furthermore, the gate 350 can be placed in
several positions between the extreme position shown in FIGS. 3-6.
The positioning of the gate 350 in these other positions regulates
the flow of the frozen product 132 from the spout 130. In addition,
the movement of the gate 350 from the open position (shown in FIGS.
3 and 5) to the closed position (shown in FIGS. 4 and 6) allows the
gate 350 to shear or break up any frozen product 132 or added
products, such as, for example, chunks of fruit, nuts, chocolate or
other ingredients that have been added to the frozen product 132.
In this shearing action, the dispensing valve 320 is less prone to
clogging when compared to conventional valves. In addition to
prevent clogging, the gate opening 355 (FIGS. 3 and 4); 740-744
(FIG. 7); 820 (FIG. 8-9) and 1040 (FIG. 10) is of sufficient size
to allow the free flow of the added products from the spout
130.
[0092] The movement of the gate 350 can be manual actuated by an
operator of the dispensing system 100. In addition, the movement of
the gate 350 can be mechanically actuated by an actuator 155 that
is connected via line 153 to the controller 150 (shown in FIG. 1).
In this embodiment, the controller 150 receives an input relating
to the desired amount that has been selected by the customer and
then instructs the actuator 155 to open the gate 350. The
controller 150 will then determine the amount of force to apply to
the piston 126 over an predetermined amount of time or a
predetermined displacement of the piston 126 to dispense the
desired amount of frozen product 132 and then instruct the actuator
155 to close the gate 350.
[0093] In FIGS. 3-6, the gate 350 is shown to having linear
movement. However, as shown in FIGS. 7-13, the movement of the gate
350 can take several forms other than linear movement. In one
embodiment, as shown in FIG. 7, the dispensing valve 700 connected
to the spout 130 provides rotational movement. In this embodiment,
the dispensing valve 700 includes a valve body 702 having a gate
housing 720. A pivot 730 rotatably connects the gate housing 720 to
a gate wheel 710. As such, the gate wheel 710 is rotatable about
the pivot 730. Further, in this embodiment, the gate wheel 710 has
a plurality of openings 740, 742 and 744, and preferably the gate
wheel 710 has at least one area that does not contain a hole, as
shown by the position of the dispensing valve 700 in FIG. 7. The
closed area stops dispensing of the frozen product 132. To dispense
the frozen product 132, the gate wheel 710 is positioned such that
one of the openings 740, 742 and 744 is co-axial with the spout end
333 (shown in FIG. 3). In the embodiment shown in FIG. 7, the
openings 740, 742 and 744 all have different geometric shapes. It
should be appreciated that the geometric shapes of the openings
740, 742 and 744 can optionally be identical. In addition, the
embodiment shown in FIG. 7 illustrates a plurality of opening 740,
742 and 744 located in the gate wheel 710. It should be appreciated
that the gate wheel may have more or less openings as required by
the particular dispensing system 100.
[0094] In another embodiment, as shown in FIGS. 8 and 9, the
dispensing valve 810 also provides rotational movement. In this
embodiment, the dispensing valve 810 includes a gate body 814 that
is connected to the spout 130. A rotating gate 812 is rotatably
attached to gate body 814. The rotating gate 812 includes an
opening 820. To dispense frozen product 132, the rotating gate 812
is rotated until the opening 820 is coaxial with a spout opening
822, as shown in FIG. 8. To prevent dispensing of the frozen
product 132, the rotating gate 812 is rotated until the gate
opening 820 is no longer coaxial with the spout opening 822 and the
spout opening 822 is completely blocked (as shown in FIG. 9).
[0095] In a related embodiment, as shown in FIGS. 10 and 11, the
dispensing valve 1010 is connected to the spout 130. This
embodiment also includes a valve body 1020 and a rotating gate 1030
having an opening 1040. However, in this embodiment, the rotating
gate 1030 is positioned within the valve body 1020. As such, the
rotating gate 1030 rotatably moves within the valve body 1020. To
dispense frozen product 132, the rotating gate 1030 is positioned
such that the spout end 333 is coaxial with the gate opening 1040
(as shown in FIG. 10). To prevent frozen product 132 from being
dispensed, the rotating gate 1030 is positioned such that opening
1040 is not coaxial with the spout end 333, and the spout end 333
is completely blocked (as shown in FIG. 11).
[0096] In yet another embodiment, as shown in FIGS. 12 and 13, the
dispensing valve 1200 has a linearly-activated gate 1210 having a
guide slot 1240. In this embodiment, a gate body 1220 is connected
to the spout 130. The gate body includes a conical end 1250 and a
guide pin 1242. The gate 1210 is movably connected to the gate body
1220 such that the guide pin 1242 is positioned in the guide slot
1240. The gate 1210 has an end portion 1232 in which an opening
1230 is formed. The end portion 1232 is also conically-shaped in
correspondence with the conical shape of the conical end 1250 of
the gate body 1220. As shown in FIGS. 12 and 13, the opening 1230
can have a star-shaped geometry. However, it should be appreciated
that the geometrical shape of the opening can optionally be, for
example, a circle. To prevent the dispensing valve 1200 from
dispensing frozen product 132, the gate 1210 is moved such that the
guide pin 1242 is positioned at a first end 1244 of guide slot
1240. This closed position also corresponds to the conical end 1250
of the gate body 1220 to contact the opening 1230 of the gate 1210.
To allow frozen product 132 to be dispensed from the dispensing
valve 1200, the gate 1210 is moved such that the guide pin 1240 is
positioned at a second end 1243 of the guide slot 1242. This open
position also corresponds to the opening 1230 not being in contact
with conical end 1250 of the valve body 1220.
[0097] In summary, the dispensing system 100 of the present
invention dispenses a desired portion of frozen product 132 at a
uniform rate from a product container 120. The product container
120 has a spout 130 and a dispensing valve 320 connected to the
spout 130. The dispensing valve 320 is used to seal the product
container 120 after filling, and the dispensing valve 320 is also
used to regulate the flow of frozen product 132. A label 170 is
attached to the product container 120 to provide information
relating to the frozen product 132. The data from label 170 is
supplied to a controller 150 by a reader 160. Based on the
information from the label 170, the controller 150 controls the
force (F) applied by a drive 144 to the product container 120 in
order to dispense the frozen product 132 at a uniform rate. The
product container 120 is sufficiently rigid such that it is not
deformed when force is applied to dispense the frozen product 132.
The product container 120 is also sufficiently deformable so that
it is collapsible when the product container 120 is empty of frozen
product 132. In addition, a position sensor 125 is connected to the
controller 150 to determine the volume of frozen product 132 in the
product container 120 and when the product container 120 is empty
of frozen product 132. As such, the present invention is not
limited to the embodiments shown in the drawings. The drawings
contained herein are for a preferred system embodiment and serve to
illustrate the operation of the present invention.
[0098] 3. Method of Operation
[0099] As shown in FIGS. 14-16, one embodiment the present
invention includes a preferred method for dispensing frozen product
132. The flow charts shown in FIGS. 14, 15 and 16 are function in
nature and the controller 150 is suitably programmed to implement
these functions. Furthermore, while the following presents these
functions in a preferred embodiment as steps in a sequence, it is
to be expressly understood that changes in the order of the
sequence could occur without departing from the teachings of the
present invention. Generally, in the method of the present
invention, frozen product 132 is dispensed from a dispensing system
100 at a uniform rate to deliver a portion regardless of the
formulation of the frozen product 132.
[0100] As shown in FIG. 14, information relating to the frozen
product 132 is provided on the product container 120 (step 1400).
In particular, the information can include the formulation,
temperature requirements, force requirements linear displacement of
the piston 126 or constant information, etc. This information in
part allows the frozen product 132 to be dispensed at a uniform
rate. The information is read from the product container 120 (step
1410). In one embodiment, the information can be read by reading a
label 170 that is attached to the product container 120 using
reader 160, and the label 170 information is supplied to the
controller 150. The information is typically identified when the
product container 120 is placed into the dispensing system 100 and
should only changed when the product containers 120 are changed.
Once the information has been read, the formulation of the frozen
product 132 is displayed (step 1415). The formulation is typically
displayed by a display device 172 that is connected to the
controller 150 and the housing 102 of the dispensing system
100.
[0101] In addition, the desired amount of frozen product 132 is
also determined (step 1420) through a portion input 1425. The
desired amount of frozen product 132 is typically the amount of
frozen product 132 that has been purchased by a customer. The
desired amount may be selected by either the customer or an
operator of the dispensing system 100. In one automated embodiment,
the dispensing system 100 allows the customer or the operator to
select the desired portion through an input device 101 connected to
the controller 150 and, optionally, the housing 102. Also, in an
automated dispensing system 100, the desired amount can be
determined by the amount of money the customer input into the
dispensing system 100.
[0102] The amount of frozen product 132 left in the product
container 120 is then determined (step 1430). The amount of frozen
product can be determined by the position of the piston 126 in the
product container 120. The amount of frozen product 132 in the
product container 120 is compared to the desired amount of product
(step 1440). If the desired amount of frozen product 132 is greater
than the amount in the product container 120, the product container
120 is replaced (step 1450). Also, it should be noted that the
actual amount in the product container 120 can be dispensed and,
after the product container 120 is replaced, the remainder of the
desired amount can be dispensed. However, this dispensing option is
dependent upon both the empty and newly added product containers
120 having the same formulation.
[0103] If the desired amount is less than the amount in the product
container 120, the temperature of the frozen product 132 is
determined (step 1460) through a temperature input 1465. The
temperature can be determined by a temperature sensor 162 that is
positioned near the product container 120.
[0104] From the parameters of temperature and formulation, the
controller 150 determines a force (F) for application to a piston
126 in the product container 120 (step 1470). In another aspect of
the present invention, the time that the force (F) should be
applied to the piston is determined (step 1472). The pre-determined
force (F) is applied, monitored and varied based on the parameters
of temperature (1465), time (1486), force (1485) and formulation of
the frozen product 132 (step 1474). The pre-determined force is
varied by a feedback loop 151 connected to the controller 150, such
as, for example, a proportional integral differential (PID)
feedback loop. Due to the force (F) applied to the piston 126 in
step 1474 by the feedback loop 151, the frozen product 132 is
dispensed at a uniform rate (step 1480). The controller 150
continuous measures the force (F) applied to the piston 126 and the
time that the force is applied to ensure that the correct amount of
force (F) is being applied to dispense the desired portion of
frozen product 132 at a uniform rate.
[0105] Next, the controller 150 determines whether the desired
amount of frozen product 132 has been dispensed (step 1490) through
an amount dispensed input 1475. If the desired amount of product
132 has been dispensed, the dispensing system 100 stops dispensing
frozen product 132 (step 1495). However, if the desired amount of
frozen product 132 has not been dispensed the temperature of the
frozen product 132 is again determined (step 1460), the force (F)
is applied to the piston 126 of the product container 120 (step
1470) and the frozen product 132 is dispensed at a uniform rate
(step 1480). In this embodiment, the determination of the
dispensing of the desired amount can be made by measuring the
amount of time that the frozen product 132 is dispensed at the
constant rate from the spout 130. It should be noted that the query
of checking whether the desired amount of frozen product 132 has
been dispensed can be made several times during dispensing the
frozen product 132. In addition, the force (F) is monitored by the
controller 150 using force sensor 164 and input through the applied
force input 1485. As a result of this monitoring and the feedback
loop 151, the force (F) applied to the piston 126 in the product
container 120 is constantly adjusted (step 1474) to ensure that the
frozen product 132 is dispensed at a constant rate. Once the
desired amount has been dispensed, the dispensing system 100 stops
dispensing frozen product 132 (step 1495).
[0106] In another embodiment of the method of the present
invention, as shown in FIG. 15, the portion control features are
not included. In this embodiment, an operator dispenses the frozen
product 132 at a uniform rate and gauges the desired amount of
frozen product 132 that has been dispensed. First, information is
provided on the product container 120 (step 1500). The information
is read from the product container 120 (step 1510). The information
can include the formulation, the temperature, linear displacement
of the piston 126 the force (F) required to dispense the frozen
product 132 at a uniform rate or a constant value. The product
information can be stored in memory of the controller 150, and the
information can be accessed by a label 170 that is connected to the
product container 120. The label 170 is read by a reader 160
connected to the controller 150 when the product container 120 is
installed into the dispensing system 100. The information from the
label 170 is supplied to the controller 150, and the controller 150
determines the force (F) to apply to the piston 126 such that the
frozen product 132 is dispensed at a uniform rate. The formulation
of the frozen product 132 is displayed (step 1515). The display
typically comprises a sign 172 connected to the controller 150 and
to the housing 102 of the dispensing system 100. In this
embodiment, the desired amount of frozen product 132 that is to be
dispensed is determined (step 1520). Once the desired amount has
been determined, the force (F) required to dispense the desired
amount is determined (step 1525). The frozen product 132 is
dispensed from the dispensing system 100 at a uniform rate (step
1530). The uniform dispensing rate is determined by utilizing
temperature input 1532, dispensed product input 1534 and an applied
force input 1536. This uniform dispensing rate allows an operator
to easily gauge the amount of frozen product 132 that has been
dispensed regardless of the formulation of the frozen product 132.
Once the desired amount has been dispensed, the dispensing of the
frozen product 132 (step 1540). The uniform dispensing rate allows
the operator to determine the amount of frozen product 132 that is
dispensed and, therefore, less frozen product 132 is wasted.
[0107] In even another embodiment, as shown in FIG. 16, the frozen
product 132 is automatically dispensed by monitoring at least the
linear displacement of the piston 126. First, information relating
to the frozen product 132 is provided on the product container 120
(step 1600). The information is read from the product container
(step 1610). The information can include the formulation, the
temperature, the linear displacement of the piston 126 and the
pre-load force (F). The product information can be stored in memory
in the controller 150, and the information can be accessed by
correlation to a label 170 that is connected to the product
container 120. The label 170 is read by a reader 160 connected to
the controller 150 when the product container 120 is installed into
the dispensing system 100. The information is supplied to the
controller 150, and the formulation of the frozen product is
displayed to the customer (step 1615). In step 1620, a pre-load
force is determined (step 1620). The controller 150 then uses the
information supplied from the step 1610 to apply a pre-load force
(F) to the piston 126 (step 1625). This pre-load force (F)
compresses the frozen product 132 to remove most of the air that is
present in the frozen product 132.
[0108] Further, the desired amount of frozen product 132 is
determined (step 1630). In one embodiment, the desired amount can
be determined by a plurality of switches, touch pad or other
suitable input devices 101 that are connected to the controller
150. In addition, it should be understood that determining the
desired amount of frozen product 132 can be accomplished by any
other suitable procedure or technique known in the art.
[0109] Once the desired amount is determined, an additional force
is determined (step 1635). The additional force is a force that is
above and beyond the pre-load force. The additional force is used
to dispense the desired portion of frozen product 132. The
controller 150 monitors the linear displacement of the piston 126
(step 1640). This monitoring of the linear displacement of the
piston 126 is based upon the pre-load force (F) and additional
force (1647), the formulation of the frozen product (1648) and the
temperature of the frozen product (1649). The linear displacement
of the piston 126 is a distance measurement that the piston 126
must travel in order for the desired amount of frozen product 132
to be dispensed. For example, in one embodiment, the displacement
of the piston 126 is based on the (a.) formulation, (b.) pre-load
force (F), (c.) additional force and the (d.) temperature. As such,
in one example, the displacement could correspond to one (1)
centimeter of piston 126 displacement equals five (5) milliliters
of frozen product 132 dispensed. This example is for illustration
only and should not be construed to limit the present
invention.
[0110] Once the additional force has been determined and the linear
displacement monitored, the dispensing valve 320 is opened (step
1650). The additional force is applied to piston 126 (step 1655).
During application of the additional force, the temperature is
monitored (step 1656). If the additional force exceeds the maximum
or minimum force limits required by the dispensing system 100, the
temperature is increased or decreased based on the value of the
applied force (step 1658). For example, it should be noted that the
force (F) can have a maximum and a minimum force limit based on the
requirements of the dispensing system 100. In the event that the
force applied to the piston 126 exceeds the maximum force limit,
the temperature of the frozen product 132 can be increased by the
controller 150 that is connected to a temperature control (not
shown) in the housing 102. In the event that the force applied to
the piston 126 is less than the minimum force, the temperature of
the frozen product 132 can be decreased by the controller 150. It
should be appreciated that due to the volume of the frozen product
132 in the product container 120 such changes in temperature occur
over a particular amount of time and, therefore, do not occur
instantaneously.
[0111] As such, the desired amount of frozen product 132 is
dispensed at a uniform rate (step 1660). As shown in step 1660,
during the dispensing of the frozen product 132, the inputs of the
temperature (1662), force (1664) and the piston 126 position (1666)
are monitored by the controller 150. In this monitoring, the
controller 150 can use all or some of these inputs as a control
input to a feedback loop 151, such as, for example, a proportional
integral differential (PID) feedback loop. This feedback loop 151
can vary some or all of the parameters to ensure that the frozen
product 132 is dispensed at a uniform rate.
[0112] Once the piston 126 has been displaced by the amount of
linear displacement determined in step 1645, the force is reduced
(step 1670), and the dispensing valve 320 is closed when the
desired amount of frozen product 132 has been dispensed (step
1675). In reducing the force (step 1670), the additional force is
reduced after the desired frozen product has been dispensed. In
addition, the preload force can also be reduced to prevent loss or
run-off of the frozen product 132.
[0113] The above-described embodiments of the method of the present
invention ensures that the frozen product 132 is dispensed at a
uniform rate regardless of the formulation of the frozen product
132 because the force (F) applied to the piston 126 is constantly
adjusted based on various parameters associated with the frozen
product 132. In addition, dispensing at a uniform rate allows a
determination of the amount that is to be dispensed, and the
dispensing system 100 can dispense the desired amount of frozen
product 132 without wasting the frozen product 132 or shorting the
customer out of the actual amount of frozen product 132 that has
been purchased.
[0114] The foregoing discussion of the invention has been presented
for purposes of illustration and description. Further, the
description is not intended to limit the invention to the form
disclosed herein. Consequently, variation and modification
commensurate with the above teachings, within the skill and
knowledge of the relevant art, are within the scope of the present
invention. The embodiment described herein and above is further
intended to explain the best mode presently known of practicing the
invention and to enable others skilled in the art to utilize the
invention as such, or in other embodiments, and with the various
modifications required by their particular application or uses of
the invention. It is intended that the appended claims be construed
to include alternate embodiments to the extent permitted by the
prior art.
* * * * *