U.S. patent application number 11/476898 was filed with the patent office on 2007-01-18 for portable thermal treatment and storage units for containing readily accessible food or beverage items and methods for thermally treating food or beverage items.
Invention is credited to Thomas G. Kaplan.
Application Number | 20070012068 11/476898 |
Document ID | / |
Family ID | 38366905 |
Filed Date | 2007-01-18 |
United States Patent
Application |
20070012068 |
Kind Code |
A1 |
Kaplan; Thomas G. |
January 18, 2007 |
Portable thermal treatment and storage units for containing readily
accessible food or beverage items and methods for thermally
treating food or beverage items
Abstract
A portable thermal treatment and storage unit includes a housing
with a thermal treatment chamber, and ports that provide a flow
path between the chamber and an environment surrounding the unit to
facilitate a flow of air into the housing, through the chamber, and
out of the housing. The unit is configured to selectively open and
close at least one port to limit or prevent the flow of air into
the housing and through the chamber such that, when the at least
one port is opened, the unit facilitates heat transfer between the
flowing air and the food or beverage items supported by the support
member so as to change the temperature of the food or beverage
items. When the at least one port is closed, the unit insulates the
food or beverage items to maintain the food or beverage items
within a selected temperature range for a selected time period.
Inventors: |
Kaplan; Thomas G.; (North
Potomac, MD) |
Correspondence
Address: |
EDELL, SHAPIRO & FINNAN, LLC
1901 RESEARCH BLVD.
SUITE 400
ROCKVILLE
MD
20850
US
|
Family ID: |
38366905 |
Appl. No.: |
11/476898 |
Filed: |
June 29, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11430198 |
May 9, 2006 |
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11476898 |
Jun 29, 2006 |
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60697984 |
Jul 12, 2005 |
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60697985 |
Jul 12, 2005 |
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60697986 |
Jul 12, 2005 |
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60702298 |
Jul 26, 2005 |
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Current U.S.
Class: |
62/457.5 ;
62/371; 62/530 |
Current CPC
Class: |
B65D 81/3823 20130101;
F25D 2303/0831 20130101; F25D 2331/809 20130101; A23L 3/36
20130101; F25D 17/06 20130101; B65D 81/3862 20130101; B65D 2205/02
20130101; F25D 17/045 20130101; F25D 2331/812 20130101; B65D 81/382
20130101; B65D 5/6635 20130101; F25D 3/08 20130101 |
Class at
Publication: |
062/457.5 ;
062/530; 062/371 |
International
Class: |
F25D 3/08 20060101
F25D003/08 |
Claims
1. A portable thermal treatment and storage unit comprising: a
housing including a thermal treatment chamber; and a plurality of
ports disposed on the unit, the ports providing a flow path between
the chamber and an environment surrounding the unit to facilitate a
flow of air into the housing, through the chamber, and out of the
housing; wherein the unit is configured to selectively open and
close at least one port to limit or prevent the flow of air into
the housing and through the chamber such that, when the at least
one port is opened, the unit facilitates heat transfer between the
flowing air and the food or beverage items supported by the support
member so as to change the temperature of the food or beverage
items and, when the at least one port is closed, the unit insulates
the food or beverage items to maintain the food or beverage items
within a selected temperature range for a selected time period.
2. The unit of claim 1, further comprising a lid that is removably
securable to an open end of the housing, wherein the lid includes
at least one port and the housing includes at least one port
disposed on a side wall of the housing.
3. The unit of claim 2, wherein the lid is suitably dimensioned to
fit over a bottom end of the housing so as to close the at least
one port on the housing side wall.
4. The unit of claim 2, further comprising a divider disposed
within the thermal treatment chamber, wherein the divider separates
the chamber into a plurality of sub-chambers.
5. The unit of claim 4, wherein each sub-chamber corresponds with
at least one port.
6. The unit of claim 4, wherein each port corresponds with a single
sub-chamber, and each sub-chamber corresponds with at least two
ports.
7. The unit of claim 1, further comprising: a plurality of cups
configured to be received and retained within the thermal treatment
chamber, wherein each of the cups includes a food or beverage item
disposed within the cups and a removable lid that encloses an
opening in the cup, and the food or beverage item fills a selected
portion of the cup while leaving an air gap between an upper
portion of the food or beverage item disposed within the cup and an
underside of the lid connected with the cup, the air gap having a
thickness of between about 0.25 inch and about 0.5 inch.
8. The unit of claim 7, wherein the food or beverage item disposed
within the cups comprises one of a slush beverage product and a
dairy product.
9. The unit of claim 7, wherein the food or beverage item disposed
within the cups comprises a slush beverage product including at
least one fruit juice and at least one of a nucleating agent,
pectin, carrageenan, cellulose gum, cellulose gel, xantham gum,
locust bean gum and guar gum.
10. A portable thermal treatment and storage unit comprising: a
housing including a thermal treatment chamber; and a means for
selectively opening and closing an airflow path between the chamber
and an environment surrounding the unit, wherein opening of the
flow path facilitates a flow of air into the housing, through the
chamber, and out of the housing and a heat transfer between flowing
air and the food or beverage items suspended within the chamber so
as to change the temperature of the food or beverage items
suspended within the chamber; wherein the unit is suitably
insulated such that, upon closing the airflow path after the food
or beverage items to change the temperature of the food or beverage
items, the unit maintains the food or beverage items within a
selected temperature range for a selected time period.
11. A method of thermally treating food or beverage items, the
method comprising: loading frozen food or beverage items in a unit
such that each food or beverage item is disposed within a chamber
of the unit; thermally treating the frozen food or beverage items
by facilitating a flow of air from an environment surrounding the
unit through the unit chamber, wherein the air is at a higher
temperature than the frozen food or beverage items such that the
frozen food or beverage items are warmed over a selected warming
time period to form partially frozen food or beverage items at a
selected temperature range that is higher than the temperature of
the frozen food or beverage items; and upon achieving the selected
temperature range for the partially frozen food or beverage items,
limiting or preventing the flow of air through the unit chamber so
as to maintain the partially frozen food or beverage items within
the selected temperature range for a selected storage time
period.
12. The method of claim 11, wherein the partially frozen food or
beverage items comprises one of a slush beverage product and a
partially frozen dairy product.
13. The method of claim 11, wherein the partially frozen food or
beverage item comprises a slush beverage product including at least
one fruit juice and at least one of a nucleating agent, pectin,
carrageenan, cellulose gum, cellulose gel, xantham gum, locust bean
gum and guar gum.
14. The method of claim 13, wherein the frozen food or beverage
items have a temperature within the range of about 10.degree. F. to
about -40.degree. F. when the food or beverage items are loaded
within the unit.
15. The method of claim 11, wherein the air flowing from the
environment surrounding the unit is at a temperature within a range
of about 35.degree. F. to about 41.degree. F.
16. The method of claim 15, wherein the warming time period is at
least about 12 hours.
17. The method of claim 15, wherein the warming time period is no
greater than about 24 hours.
18. The method of claim 11, wherein the food or beverage items are
disposed within a plurality of cups that are loaded within the unit
such that each cup is disposed within the chamber, each cup
includes a removable lid that encloses an opening in the cup, and
the food or beverage item fills a selected portion of the cup while
leaving an air gap between an upper portion of the food or beverage
item disposed within the cup and an underside of the lid connected
with the cup, the air gap having a thickness of between about 0.25
inch and about 0.5 inch.
19. The method of claim 11, wherein the unit comprises a housing
including the chamber disposed therein and a lid that is removably
secured over an open end of the housing, the lid includes at least
one port and the housing includes at least one port on a sidewall
of the housing.
20. The method of claim 19, wherein the limiting or preventing of
air flow through the unit chamber comprises removing the lid from
the open end of the housing and securing the lid over a bottom end
of the housing so as to close the at least one port on the housing
side wall.
21. The method of claim 19, wherein the unit further comprises a
divider disposed within the chamber, wherein the divider separates
the chamber into a plurality of sub-chambers.
22. The method of claim 21, wherein a single food or beverage item
is placed within each sub-chamber.
23. The method of claim 21, wherein each sub-chamber corresponds
with at least one port.
24. The method of claim 21, wherein each port corresponds with a
single sub-chamber, and each sub-chamber corresponds with at least
two ports.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 11/430,198, entitled "Portable Thermal
Treatment and Storage Units for Containing Readily Accessible Food
or Beverage Items and Methods for Thermally Treating Food or
Beverage Items," and filed May 9, 2006, which claims priority from
the following U.S. Provisional Patent Application Ser. Nos.
60/697,984, entitled "Refrigeration Unit for Food Service Portion
Cups and Process Thereof", and filed Jul. 12, 2005; 60/697,985,
entitled "Refrigeration Unit for Making Slush Beverages Without a
Slush Machine, and Process Thereof", and filed Jul. 12, 2005;
60/697,986, entitled "Portable Refrigeration Unit With Ready
Access", and filed Jul. 12, 2005; and 60/702,298, entitled
"Portable Insulation Unit for Partially Frozen Beverages With Ready
Access", and filed Jul. 26, 2005. The disclosures of these patent
applications are incorporated herein by reference in their
entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention pertains to a portable unit for
thermally treating and/or maintaining food or beverage items at
desired temperatures for select periods of time. The present
invention further pertains to methods for thermally treating food
or beverage items to achieve a desired temperature and partially
frozen state for such items.
[0004] 2. Description of the Related Art
[0005] Many foodservice operations offer individual containers of
food or beverage items requiring continuous freezing or
refrigeration at the point of service to the consumer. Typical
items of this nature include foods and beverages prepackaged by a
supplier for delivery to a foodservice end point or point-of-sale
location, where the supplier's prepackaging is in containers
containing a sufficient quantity for consumption by a single
consumer and is stored and displayed in a frozen or refrigerated
state, as well as food and beverage items prepared and dispensed
from machines at the point of sale.
[0006] Examples of such prepackaged items include, without
limitation, cups of hard-frozen or soft ice cream, frozen yogurt,
sherbet, jellos, puddings, fruit cups, liquid juices, and frozen
fruit-flavored confections commonly referred to as "Italian Ice,"
popsicles, and the like. A number of suppliers have recently
introduced a related category of items formulated so as to maintain
a partially frozen state even when subjected to the relatively low
temperature range of commercial freezers. These items include "soft
frozen lemonade," and similar items designed to be soft enough to
be pushed from the package through an opening in the package, for
immediate consumption.
[0007] Examples of items that have not been prepackaged include
beverages dispensed from machines that have converted the beverage
from a liquid to a partially frozen state that is appealing to
consumers. Such beverages are frequently referred to within the
beverage industry as "frozen uncarbonated beverages," "frozen
carbonated beverages" or milkshakes, and are commonly referred to
by consumers as a "slushy," a "smoothie," a "slurpee" ("Slurpee" is
a registered trademark of the 7-11 Corporation), an "Icee," ("Icee"
is a registered trademark of the J & J Snack Foods
Corporation), a "shake," a "frappe," a or a "cabinet shake." These
types of beverages and all similar beverages are collectively
referred to herein as "slush beverages" or "slush beverage
product", or milkshakes. The machines used to convert such
beverages from a liquid to a partially frozen state are commonly
known as "slush machines," or "milkshake machines," or "soft-serve
machines." These types of machines and all machines performing a
similar function are collectively referred to herein as "slush
machines" or "milkshake machines."
[0008] There are numerous drawbacks to the currently available
refrigeration devices that are used for maintaining such food or
beverage items, whether prepackaged or not, in the desired state
and at the desired temperatures for point-of-sale use. In
particular, refrigeration for display to consumers is typically
expensive, and requires a lot of counter space or floor space as
well as routine maintenance. For example, the slush or granita
machines, as described above, typically require a source of
electricity, a compressor for freezing a surface in contact with
the initially liquid beverage, and an augur or other device for
agitating the beverage as it freezes and preventing the formation
of objectionably large ice crystals. In addition, such machines are
expensive, require periodic maintenance, require the replacement of
parts that wear with use, and require periodic disassembly and
reassembly for cleaning.
[0009] In addition, many foodservice operations offering food items
such as slush beverages must serve relatively high numbers of
customers in relatively short periods of time. For example, because
of the popularity of slush beverages, particularly with children,
foodservice operations, such as school cafeterias, must be capable
of dispensing a high volume of slush beverage product in a short
period of time. Dispensing high volumes of such products from such
machines requires a significant expenditure of labor. Further, many
of the models of slush machines in current use are limited in
capacity to the amount of beverage product initially poured into
the product reservoirs of the machine plus the small additional
amount that can practicably be added to the machine and frozen to
the desired consistency during the serving period. As a result,
such high-volume foodservice operations may be unable to prepare
and dispense from a single machine a sufficient amount of slush
beverage in the allotted serving time. Thus, multiple machines
would be required to achieve the desired volume of slush beverage,
which leads to increased equipment and maintenance costs for a
particular foodservice operation.
[0010] Some foodservice operations attempt to overcome this problem
by dispensing cups of slush beverage from the machine prior to the
first period of service to customers, thereby creating capacity
within the reservoirs of the machine for additional liquid beverage
to be added with the result that it may freeze into the desired
state in time for the first period of service to customers.
However, this approach is not very effective. Slush beverages are
typically dispensed at a temperature in the range of about
23.degree. F. (-5.degree. C.) to about 29.degree. F. (-1.7.degree.
C.), and it is important to maintain the beverage at a temperature
close to the temperature at which it was dispensed. If stored at
too cold a temperature, additional ice forms within the beverage,
which renders it too viscous to be easily consumed. In contrast, if
the slush beverages are stored at too warm a temperature, the
beverage will melt, which renders it less appealing to
consumers.
[0011] It is not desirable to store dispensed slush beverage in the
freezer of a typical foodservice operation, because such freezers
generally maintain an interior temperature of 10.degree. F.
(-12.degree. C.) or colder, at which temperature additional ice
would form within the slush beverage and it would eventually freeze
solid. Nor is it desirable to store dispensed slush beverage in the
cooler or refrigerator of a typical foodservice operation, because
such coolers and refrigerators generally maintain an interior
temperature between about 35.degree. F. (1.67.degree. C.) and about
41.degree. F. (5.degree. C.), at which temperature the slush
beverage, having been dispensed in the range of about 23.degree. F.
(-5.degree. C.) to about 29.degree. F. (-1.7.degree. C.), would
begin to melt. Finally, it is least desirable to place dispensed
slush beverage on a serving line exposed to ambient air within the
foodservice operation, because such air, typically in the range of
about 72.degree. F. (22.degree. C.) to about 85.degree. F.
(29.degree. C.) or warmer, would cause the slush beverage rapidly
to melt.
[0012] In addition, many foodservice operations with multiple
serving lines or points of service outside the main cafeteria, lack
the ability to transport cups of slush beverage or milkshake from
the slush machine or milkshake machine to such locations that
increase the opportunity for additional sales without risk of
melting the beverage.
[0013] One approach to providing a partially frozen slush beverage
product or a milkshake product at a desirable and aesthetically
pleasing consistency is to thaw or temper a hard frozen product
prior to serving. For example, a plurality of articles of a frozen
beverage contained within a single case may be tempered to a
suitable consistency for consumption by placing the case into a
refrigerator or walk-in cooler for a sufficient amount of time, and
can be further thermally treated so as to remain in a state
suitable for consumption for a matter of hours, before the
proportion of ice in the product declines to the point at which the
product lacks the desirably cold mouth-feel.
[0014] This approach is practical and advantageous to both the
foodservice operation and the consumer only within significant
limitations on the number of articles of the frozen beverage
contained within a single case, the rate of heat transfer provided
by the case between the ambient air and the product within the case
so as to achieve optimal product appeal within a practical amount
of time, and the freezing point of the beverage product within the
case. In particular, a typical case containing packs of, for
example, 12, 24 or 48 articles would require an inconveniently long
time to temper under refrigeration. Further, a case that does not
permit sufficient heat transfer from the ambient air in the cooler
to the beverage product, or that permits too rapid a heat transfer,
will result in a beverage respectively too firm or too melted to be
appealing to consumers. In addition, the amount of time needed to
temper to a desirable consistency will depend on the freezing point
of the beverage, which in turn will depend upon the amount of
solids (i.e., non-aqueous compounds) in the composition of the
beverage. For example, milkshakes typically include solids on the
order of 22% by weight of the product, while slush beverage
products typically include on the order of 17% solids by weight of
the product. With such compositions, the necessary time to temper
within the typical case pack and with the typical case design will
typically exceed 24 hours, often extending two or more days. These
are inconveniently long timeframes for planning and preparation at
many high volume foodservice operations. While the tempering time
can be reduced by altering the composition of the product to
increase solids so as to depress the melting point, such an
approach is generally undesirable for the consumer or the
manufacturer. Increases in solids often involve adding sugars,
which increase calories to undesirable levels, or increases in
other solids such as nonfat milk solids, which increase the cost of
the product to undesirable levels.
[0015] Thus, the approach of thawing or tempering a hard frozen
product prior to serving, using conventional thermal treatment
techniques, is often undesirable and impractical, particularly for
high-volume foodservice operations and their suppliers.
[0016] The problems posed by the inherent limitations of
conventional food service preparation and/or cold storage devices
such as slush machines and milkshake machines can occur in a wide
range of high-volume foodservice operations, including cafeterias
(as noted above) and other foodservice sites operated within
schools, colleges, office buildings, government buildings,
convention centers, military feeding sites, stadiums, movie
theaters, cruise ships, passenger trains, casinos, amusement parks,
catered events, buffets, county fairs, and the like.
[0017] In particular, the above-noted problems associated with
providing a high volume of slush and/or milkshake beverages to
children in school cafeterias based upon the use of conventional
foodservice devices often results in the decision by schools to
abandon the serving of slush beverages or milkshake products to
students, despite the popularity of such beverages to students.
SUMMARY OF THE INVENTION
[0018] The present invention provides a relatively inexpensive,
portable thermal treatment and storage device or unit for food or
beverage items for point-of-sale use in foodservice locations, of
any type, which find it impractical to purchase or operate a slush
machine or milkshake machine, for any of the following reasons: the
expense of the machine; labor necessary for filling, sanitizing,
and cleaning the machine; the electrical expense associated with
providing for and operating the machine; the space requirements of
the machine; and the ongoing parts and labor expense for
maintenance of the machine. The portable thermal treatment and
storage unit is useful in low-volume foodservice operations where
the food or beverage items are to be produced or provided at a
single point-of sale, and also in high-volume foodservice
operations in which the food or beverage items are to be produced
or provided at multiple points-of-sale, where multiple slush or
milkshake machines would otherwise be required. In addition, the
portable thermal treatment and storage unit maintains the food or
beverage items in a desired state and at a desired temperature for
extended periods of time.
[0019] The present invention is not limited to the above features
and/or uses, and it is further not intended that the present
invention be construed as requiring any one or more of the above
features and/or uses unless expressly required by the claims
attached hereto.
[0020] The present invention is not limited to the above features
and/or uses, and it is further not intended that the present
invention be construed as requiring any one or more of the above
features and/or uses unless expressly required by the claims
attached hereto.
[0021] In accordance with an exemplary embodiment of the present
invention, a portable thermal treatment and storage unit comprises
a housing including a thermal treatment chamber. Ports are disposed
on at least one of the housing and support member. The ports
provide a flow path between the chamber and an environment
surrounding the unit to facilitate a flow of air into the housing,
through the chamber, and out of the housing. The unit is further
configured to selectively open and close at least one port to limit
or prevent the flow of air into the housing and through the chamber
such that, when the at least one port is opened, the unit
facilitates heat transfer between the flowing air and the food or
beverage items supported by the support member so as to change the
temperature of the food or beverage items. When the at least one
port is closed, the unit insulates the food or beverage items to
maintain the food or beverage items within a selected temperature
range for a selected time period.
[0022] The units and corresponding methods of the present invention
enhance point-of-sale foodservice operations by thermally treating
food or beverage items while minimizing costs and labor associated
with such foodservice operations. Most significantly, since the
unit is configured to convert a frozen product into a slush or
milkshake beverage product, the need for a slush or milkshake
beverage machine in foodservice operations is eliminated
altogether. Further, when utilizing the unit of the invention for
providing slush or milkshake beverages, the unit eliminates the
need for multiple slush or milkshake beverage machines disposed at
different locations in order to ensure that the requisite volume of
such beverages is available for consumption over a select time
period. The unit of the present invention further requires no
electrical energy or mechanical devices such as compressors to
ensure effective refrigeration of food and beverage items.
[0023] The above and still further objects, features and advantages
of the present invention will become apparent upon consideration of
the following detailed description of specific embodiments
thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is an exploded view in perspective of a portable unit
for insulating and refrigerating food or beverage items for
point-of-sale consumption in accordance with the present
invention.
[0025] FIG. 2 is a cross-sectional side view in elevation of the
cartridge of the unit of FIG. 1.
[0026] FIG. 3 is a top view in plan of the cartridge top section of
the unit of FIG. 1.
[0027] FIG. 4 is a view in perspective showing a bottom surface of
the cartridge bottom section of the unit of FIG. 1.
[0028] FIG. 5 is a cross-sectional side view in elevation of the
outer insulating case of the unit of FIG. 1.
[0029] FIG. 6 is a view in perspective of a plurality of stacked
units having the same configuration as the unit of FIG. 1.
[0030] FIG. 7 is an exploded view in perspective of a portable
thermal treatment unit for thermally treating and storing food or
beverage items for point-of-sale consumption in accordance with the
present invention.
[0031] FIGS. 8A and 8B are top views of the housing for the unit of
FIG. 7 showing a movable member disposed within the housing at two
different positions.
[0032] FIGS. 9A and 9B are views in perspective for the unit of
FIG. 7 in which the movable member is disposed within the housing
at the two different positions as depicted in FIGS. 8A and 8B.
[0033] FIG. 10 is a top view of the unit of FIG. 7.
[0034] FIG. 11 is a cross-sectional side view of the unit of FIG.
7.
[0035] FIG. 12 is an exploded view in perspective of a portable
thermal treatment unit for thermally treating and storing food or
beverage items for point-of-sale consumption in accordance with
another embodiment of the present invention.
[0036] FIG. 13 is a view in perspective of the unit of FIG. 12
during thawing of food or beverage items within the unit.
[0037] FIG. 14 is another view in perspective of the unit of FIG.
12 during display and point-of-sale implementation of the unit.
DETAILED DESCRIPTION
[0038] In accordance with the present invention, a portable thermal
treatment and storage device or unit is provided that is capable of
converting frozen or non-frozen food or beverage items into a
partially frozen state and/or maintaining food or beverage items in
a partially frozen or any other desired state and within a desired
temperature range for a selected time period without the
requirement of electrical energy.
[0039] In one embodiment of the invention, a portable refrigeration
and insulation unit includes a cartridge that effectively insulates
and/or refrigerates food items stored in the cartridge at desired
temperatures. The cartridge includes an insulating material and/or
a heat transfer material that provides effective heat transfer
between portions of the cartridge and the food items stored within
the cartridge so as to maintain the food items at the desired
temperatures. In addition, the unit includes an outer frame or case
that is configured to receive the cartridge to provide further
insulating features for the unit as well as minimize or prevent
exposure of the food items to the ambient air in which the device
is located. The outer frame is further configured to be stacked
with other outer frames to facilitate more effective storage of a
high volume or quantity of food items while minimizing floor space
at a point-of-sale foodservice location. The unit is particularly
useful for preparing slush beverage products by thermally treating
a beverage product in a liquid state so as to form a slush beverage
product in a partially frozen state within the unit, and then
thermally maintaining the slush beverage product at a desired
temperature and at the desired partially frozen state for a
selected time period.
[0040] In another embodiment of the invention, a thermal treatment
and insulation unit includes a thermal treatment feature in which
an airflow path through the unit is selectively provided during
operation of the unit. This unit design is particularly useful for
thermally treating frozen or partially frozen food or beverage
products, where the products are loaded into the unit at a
temperature that is lower than the ambient air temperature
surrounding the unit, and an airflow pathway is facilitated by
selectively opening one or more ports within the unit so as to heat
the products in a desired manner and for a selected period of time.
The unit is further configured such that the one or more ports in
the unit can be closed to substantially limit or prevent airflow
through the unit, while the unit effectively insulates the food or
beverage products loaded within the unit so as to maintain such
products at a desired temperature for a selected time period.
[0041] An exemplary embodiment of a portable refrigeration and
insulation unit of the present invention is described below and
depicted in FIGS. 1-5. The portable refrigeration and insulation
unit is described herein in relation to producing and/or storing
slush beverage products as described below while maintaining the
slush beverages in a partially frozen and aesthetically pleasing
state. However, it is noted that the unit of the present invention
is not limited to use with slush beverage products. Rather, the
unit can be used with any one or more types of different packaged
or unpackaged food or beverage items including, without limitation,
cups of hard-frozen or soft ice cream, frozen yogurt, sherbet,
jellos, puddings, fruit cups, partially frozen, frozen or liquid
juices, a fruit-flavored confections commonly referred to as
"Italian Ice," and popsicles.
[0042] Referring to FIGS. 1-5, a portable refrigeration and
insulation unit 2 includes a cartridge 4, an outer insulating case
30 with an open cavity or compartment to receive the cartridge, and
a cover 50 configured to be placed upon the outer case to close the
outer compartment of the outer case with the cartridge received
therein so as to minimize or prevent exposure as well as any
potential heat transfer between the cartridge and the ambient air
surrounding the device. Each of the outer insulating case,
cartridge and cover can be constructed of any one or more suitable
materials including, without limitation, plastics and/or metal or
metal alloy materials. Preferably, each of these components of the
unit is constructed of a lightweight and high impact resistant
thermoplastic material such as polyethylene.
[0043] Cartridge 4 and outer insulating case 30 have a generally
square configuration. The compartment of the outer insulating case
is also generally square and slightly larger in dimensions than the
outer dimensions of the cartridge so as to receive and securely
retain the cartridge when the cartridge is assembled within the
outer case in the manner described below. The cover 50 further has
a generally square configuration so as to fit snugly along a lip of
the outer case as described below. However, it is noted that the
cartridge, outer insulating case and cover may include different
geometric configurations including, without limitation,
rectangular, circular, and oval configurations. The cartridge,
outer case and cover may further include any suitable dimensions as
may be required for a particular application.
[0044] Cartridge 4 includes a top section 6 and a bottom section 20
with an open cavity or compartment suitably dimensioned to receive
the top section. The top section 6 includes a top surface plate 8
including a series of cavities or wells 10 defined in the top
surface plate and extending a selected distance from the top
surface plate. As described below, the wells 10 are configured to
receive cups of slush beverage product. However, the cavities or
wells can be configured to receive any packaged or unpackaged food
item for a particular foodservice application. In addition, the top
surface plate 8 includes a raised lip portion 7 that extends around
the periphery of the top surface plate and is configured to engage
with and slightly extend over a corresponding lip portion 21
extending around the periphery of the bottom section 20. The
cartridge top and bottom sections can be separately formed in any
suitable manner, such as an injection molding or extrusion
process.
[0045] Each of the cup wells 10 includes a closed terminal end that
is distanced from the top surface plate 8. The depth dimensions of
the wells and depth of the bottom section compartment are
preferably dimensioned such that, upon insertion of the cup wells
10 within the compartment of the bottom section 20, the enclosed
terminal ends engage with a bottom wall 22 of the bottom section
when the raised lip portion 7 of the top surface plate 8 engages
with and rests upon the lip portion 21 of the bottom section
20.
[0046] The cup wells 10 are suitably dimensioned to accommodate
slush beverage cups with any desirable sizes and geometric
configurations. For example, the cup wells may be suitably
dimensioned to receive cups in a variety of different sizes
including, without limitation, 3 ounce cups, 4-5 ounce cups, 6
ounce cups, 8 ounce cups, 10 ounce cups, 11 ounce cups and 12 ounce
cups. Further, the inner contoured surfaces of the wells are
configured to substantially complement the outer surface geometries
of the cups to be inserted within the wells so as to ensure
substantial contact is made between the cups and the inner surface
walls of the wells. This ensures effective heat exchange between
heat transfer material disposed within the cartridge and the slush
beverage product as described below.
[0047] As can be seen from the embodiment of FIGS. 1-5 (in
particular, in FIG. 2), cup wells 10 are designed with a slightly
tapered cylindrical or frustum-like configuration, in which there
is a slight decrease in cup well diameter as the wells extend from
the top plate surface 6 to their closed terminal ends. This
geometry substantially corresponds with and complements the outer
geometrical configuration of a typical slush beverage cup so as to
facilitate a tight and snug fit between the cup and the interior
cup well surface when the cup is placed within the cup well.
However, it is noted that the cup wells can have any one or more
other suitable geometric configurations to match any other outer
surface cup (or other food or beverage item) geometries for a
particular application.
[0048] The frustum-shaped cups typically used for slush beverages
have on the order of 3 to 4 square inches of surface area on the
curved wall of the cups for each fluid ounce of beverage that can
be held within the cups. Exemplary cups of this type are 6 ounce
cups having fluted walls which are manufactured by FabriKal
Corporation (Kalamazoo, Mich.). The cartridge wells can be suitably
dimensioned to receive such cups in a close fitting relationship as
described above.
[0049] The cartridge can be designed and suitably dimensioned to
include any selected number of cup wells. While the cartridge 4
depicted in the figures includes 34 cup wells, the cartridge can
include a larger or smaller number of cup wells (e.g., 10 cup
wells, 16 cup wells, 46 cup wells, 94 cup wells, etc.) depending
upon a particular application and the size of the cups to be placed
within the wells. Examples of cartridges that can be constructed in
accordance with the present invention include, without limitation,
cartridges including 16 cup wells that are configured to receive
8-12 ounce cups, and cartridges including 34 cup wells that are
configured to receive 4-5 ounce cups.
[0050] The depths of the cup wells are further suitably dimensioned
such that a majority of the outer wall surface portions of each cup
is retained within a corresponding well in which the cup is
received. For example, in the embodiment of FIGS. 1-5, the cup
wells 10 are configured to receive cups that include removable
lids, where a substantial portion of the cups (i.e., a majority of
the volume of each cup) is received within the cup wells, such that
only a small portion of each cup including the removable lid
extends from each cup well when the cups are received within the
cup wells. This cup well design ensures sufficient heat transfer
and/or insulation of the slush beverage product within the unit for
selected time periods while minimizing or preventing undesirable
heat transfer between the slush beverage product and the ambient
air surrounding the portable unit.
[0051] The cup wells can be aligned in any selected configuration
along the top surface plate of the cartridge. Preferably, the cup
wells are spaced a sufficient distance from each other and are
suitably aligned along the top surface plate of the cartridge so
that a generally uniform amount of heat transfer material and/or
insulation material surrounds each cup well. For example, the cup
wells can be spaced generally equidistant from each other to ensure
substantially uniform and effective heat transfer between the food
or beverage product disposed in each cup well and the heat transfer
material surrounding portions of the cup wells.
[0052] As can best be seen in FIG. 4, the cup wells 10 are aligned
in generally linear patterns or sets that are parallel with each
other and extend diagonally with respect to the generally square
configuration of the top surface plate 6. A series of shallow
troughs or finger engaging grooves 12 are also disposed along the
top surface plate 6 and extend between the linearly aligned sets of
cup wells 10, where the grooves 12 further extend slightly beyond
each cup well 10 disposed at the end of each linear set. Thus, each
cup well 10 includes a pair of diametrically opposed groove
sections 12 disposed about its periphery, and these finger engaging
groove sections facilitate easy removal of a cup from a cup well by
a user without unseating the cup lid. In particular, the user can
insert a thumb and forefinger into each diametrically opposed
groove section 12 adjacent a particular well 10 to facilitate easy
removal of the cup disposed within the cup well.
[0053] The top and bottom sections further include cut-out sections
disposed along the corresponding sides of both sections such that
the cut-out sections are aligned with each other upon securing the
top and bottom sections together in the manner described below. In
particular, top section 6 includes a cut-out section 14 disposed
along the peripheral lip portion 7 along one side of the top
section, while bottom section 20 includes a cut-out section 24 that
extends along the peripheral lip portion 21 as well as along the
side wall of the bottom section. The cut-out sections of the top
and bottom sections facilitate easy removal of the assembled
cartridge from the outer insulating case as described below. In
addition, cut-out section 24 of the bottom section is configured to
serve as a gripping handle to permit carrying of the assembled
cartridge by a user when the cartridge is being cleaned, thermally
treated or transported prior to use.
[0054] Optionally, an insulation section 16 is provided within
cartridge 4. The insulation section is suitably dimensioned and
configured to fit within a lower portion of the open compartment of
the bottom section 20 so as to nest snugly between the top and
bottom sections when these two sections are assembled to form the
cartridge. The insulation section is preferably formed of a
material having suitable insulating properties. Preferably, the
insulation section is formed of a closed cell foam material, most
preferably a closed cell polyethylene material. As can be seen in
FIGS. 1 and 2, insulation section 16 includes a series of tunnels
or slots 17 that extend through the insulation section. The slots
17 are further suitably dimensioned and arranged along the
insulation section so as to be aligned with and configured to
receive the cup wells 10 of top section 6 when the cartridge is
assembled in the manner described below. The insulation section 16
also includes a cut-out section 18 that generally corresponds with
the cut-out section 24 of the bottom section 20 so as to facilitate
a snug fit between the insulation section and the open compartment
of the bottom section.
[0055] When assembled in the bottom section (as shown in FIG. 2),
the insulation section surrounds portions of the cup wells 10 and
engages the bottom wall 22 so as to fill up a selected portion of
the open compartment of the bottom section, leaving a gap that
defines a remaining open volume within the open compartment to be
filled with the heat transfer material as described below. In an
exemplary embodiment, the insulation section is a closed cell foam
material (e.g., polyethylene) that is about 1.5 inches (3.8 cm) in
thickness.
[0056] Referring to FIG. 4, stepped portions are disposed along the
bottom and side walls at two adjacent corners of the bottom section
20 so as to define two ledges 26 at these corners within the bottom
section compartment. The two adjacent corner portions 19 of
insulation section 16 that correspond with ledges 26 of the bottom
section 20 are rounded or truncated to facilitate complete
insertion of the insulation section to engage with bottom wall 22
of the bottom section. An inlet port 28 to the compartment is
provided at each ledge 26 to facilitate injection or filling of the
remaining open volume in the bottom section open compartment with
heat transfer material after the insulation section 16 and top
section 6 have been inserted within the bottom section during
assembly of the cartridge. The inlet ports 28 include a valve or
any other suitable sealing structure to effectively seal the ports
after assembly of the cartridge in order to ensure that no heat
transfer material leaks from the inlet ports during operation of
the unit. The thickness of the insulation section 16 and the
locations of the ledges 26 and inlet ports 28 are selected to
ensure that the inlet ports communicate with the open space within
the bottom section compartment after the insulation section has
been installed within the bottom section.
[0057] Upon connecting the top section 6 with the bottom section 20
of the cartridge 4, a cartridge cavity exists within the cartridge
that is partially or completely filled with a heat transfer
material. For example, if the insulation section 16 is provided,
the remaining space of the cartridge cavity is filled with heat
transfer material. The cartridge cavity has a volume (also referred
to as the internal cartridge volume) that is defined by the
internal gap or space formed between the top and bottom sections
after these two sections are joined together.
[0058] The heat transfer material that is utilized in cartridge 4
is preferably a high thermal capacity phase change material such as
a refrigerant gel, liquid or other material that has a phase change
temperature (i.e., the melting point temperature of the phase
change material) that is no greater than the desired temperature
for holding the food or beverage items at a desired temperature and
in a desired state (e.g., a relatively stable partially frozen
state) for a desired period of time (e.g., for a period of about 1
hour to about 6 hours or more). The phase transfer material is most
preferably a gel material that is capable of absorbing significant
quantities of latent heat during thawing as heat is transferred
between the food or beverage item and the gel.
[0059] Preferably, the heat transfer material has a phase change
temperature that is within the range of about 1.degree. F.
(0.56.degree. C.) to about 10.degree. F. (5.6.degree. C.) below the
desired temperature range in which the food or beverage items are
to be maintained during operation of the unit. For example, typical
slush beverage products include juices that have freezing points in
the range of about 25.degree. F. (-3.9.degree. C.) to about
29.degree. F. (-1.7.degree. C.). Such slush beverage products are
often prepared and served at these temperature ranges so as to
ensure a desirable partially frozen and aesthetically pleasing
state for the beverage. In accordance with the present invention,
an ideal heat transfer material can be provided having a phase
change temperature in the range of about 22.degree. F.
(-5.6.degree. C.) to about 24.degree. F. (-4.4.degree. C.) in order
to maintain such slush beverage products at a desired partially
frozen state for extended periods of time (e.g., from about 1 hour
to about 6 hours or more). For example, an effective heat transfer
material for use in thermally treating slush beverage products with
the unit of the invention can have a phase change temperature in
the range of about 23.5.degree. F. (-4.7.degree. C.).
[0060] Preferably, the heat transfer material has a suitable
composition that effectively facilitates repeated cooling, freezing
and/or thawing of the material (e.g., at least one phase change
transfer of the material every 24 hours) without significant
degradation or decline in heat transfer performance of the heat
transfer material. Most preferably, a suitable heat transfer
material is provided that can easily withstand repeated cooling,
freezing and/or thawing cycles for a period of about two years to
about seven years or more.
[0061] The composition and volume of the phase change material, as
well as the composition and thickness of the insulation section,
can be modified in any suitable manner in the cartridge
configuration of the invention based upon a particular application
and the desired temperature range and time period in which a
particular food or beverage item is to be treated by the cartridge.
For example, in slush beverage foodservice operations, it is
desirable to provide a selected volume or amount of phase change
material within the internal cartridge volume so as to facilitate
heat transfer at an upper portion of the cups disposed within the
cup wells (i.e., a portion of the cups including the cup lids),
while insulating the cups with the insulating section disposed in
the remaining volume of the cartridge. However, in other
applications, it may be desirable to provide phase change material
within the entire internal volume of the cartridge, thus
eliminating the insulating section altogether.
[0062] The heat transfer material is filled within the internal
cartridge volume such that this material uniformly surrounds each
of the cup wells along the entire surface of the cup wells or,
alternatively, along selected portions (e.g., upper portions) of
the cup wells. For certain food and beverage storage applications,
such as slush beverage products, the amount of heat transfer
material within the cartridge is preferably selected to vary from
about 10% to about 50% of the internal cartridge volume, most
preferably at an upper portion of the internal cartridge volume
(i.e., a portion of the internal cartridge volume that extends a
selected distance from the top surface plate 8 of the top section
6). For example, for cup wells that are configured to receive and
retain cups with fluid capacities on the order of about 4-5 fluid
ounces, a suitable heat transfer material can be provided
surrounding each cup well and having a weight in the range of about
0.5 lbs (227 g). For example, the total weight of heat transfer
material that would be effective for a cartridge having 36 cup
wells (with each cup well receiving about 4-5 fluid ounces of
beverage product) would be in the range of about 18-19 lbs (8.2-8.6
kg).
[0063] Where less heat transfer material is used, the cartridge
will be lighter in weight and less costly to manufacture. However,
less heat transfer material may also result in diminished heat
transfer capabilities and resultant diminished storage time for the
food or beverage product. When the heat transfer material content
is at the low end of the range described above, the unit is
preferably constructed so as to confine the heat transfer material
within the cartridge in the manner described above, where the heat
transfer material surrounds the uppermost portions of the
cup-receiving cavities, thus ensuring maximum heat transfer from
the upper portions of the cups within the cavities, so as to
counter the effect of heat transfer into the upper portion of the
product within the cups due to exposure to ambient air.
[0064] As noted above, the heat transfer material is preferably
composed of a gel material. Most preferably, a phase change
material is used that is composed of food grade materials that are
generally recognized as safe (GRAS) by the U.S. Food and Drug
Administration. One preferable phase change material that is
suitable for use in the cartridge, particularly for use with slush
beverage products, is a gel material composed of a combination of a
natural gum polysaccharide, such as guar gum or xantham gum, and
water. In addition, the phase change material can include organic
nad/or other acids (e.g., citric or ascorbic acid), and/or salts
(e.g., alkaline salts such as chlorides, carbonates, silicates,
etc.) which serve as freezing point depressants and/or as
stabilizers for the phase change material.
[0065] An exemplary phase change material that has been found
suitable for use in the cartridge (in particular, for use with
slush beverage products) is an aqueous gel mixture including
xantham gum in an amount of no greater than about 1-2% by weight of
the total mixture, sodium chloride in an amount of no greater than
about 5% by weight of the total mixture, calcium carbonate in an
amount no greater than about 0.2% by weight of the total mixture,
sodium benzoate in an amount no greater than about 0.2% by weight
of the total mixture, and citric acid in an amount of no greater
than about 0.4% by weight of the total mixture, with the balance
being water.
[0066] Other heat transfer material compositions can also be used
in accordance with the invention, as well as compositions including
other compounds mixed with water and/or other materials. For
example, other heat transfer materials that can be used in the
cartridge of the invention can include glycols (e.g., propylene
glycols) and/or certain paraffinic hydrocarbons with suitable
melting points that facilitate desired heat transfer capabilities
for a particular foodservice application.
[0067] The cartridge 4 is assembled by first placing the insulation
section 16 within the compartment of the bottom section 20 such
that the insulation section contacts bottom surface 22 of the
bottom section. As noted above, and depending upon a particular
application in which the cartridge is to be used, the cartridge can
also be constructed without any insulation section (so that the
internal cartridge volume is capable of receiving a greater amount
of heat transfer material). The top section 6 is then inserted into
the bottom surface compartment so that the cup wells 10 extend
through the slots 17 of the insulation section and engage with
bottom surface 22 of the bottom section and the peripheral lip 7 of
the top section engages with the peripheral lip 21 of the bottom
section. Lip 7 of top section 6 is secured to lip 21 of bottom
section 20 via a suitable adhesive material (e.g., an epoxy resin)
in order to ensure that the internal cartridge volume defined
between the top and bottom sections is effectively sealed and is
liquid tight. In addition, the terminal ends of the cup wells 10
can be secured to the bottom surface 22 via the adhesive
material.
[0068] Once the top and bottom sections are effectively secured
together, with the insulation section also secured between these
two sections, the heat transfer material is then injected into the
open space or internal cartridge volume via the inlet ports 28 of
the bottom surface. Preferably, the entire open volume between the
insulation section 16 and the top surface plate 8 is filled with
heat transfer material. As noted above, the insulation section is
preferably constructed of a closed cell foam material (e.g., a
closed-cell polyethylene foam), which is substantially
non-absorbent to the heat transfer material. As shown in FIG. 2,
after filling of the cartridge in the manner described above, the
heat transfer material 29 remains within the internal cartridge
volume between the top plate of the top section and the insulation
section during use of the cartridge.
[0069] The cartridge can be constructed of any suitable materials
having a sufficient flexibility and strength to permit a slight
expansion of the heat transfer material (e.g., during freezing of
the heat transfer material) without rupturing. Portions of the
cartridge, including the top surface plate 8 and the walls of the
cup-receiving wells 10, are also preferably constructed of
materials having sufficient thermal conductivities that facilitate
rapid heat transfer between the food or beverage product and the
heat transfer material. As noted above, the cartridge is preferably
constructed of a high impact resistant, thermoplastic, easily
cleanable material, most preferably polyethylene.
[0070] The cartridge is also preferably white in color so as to
impart an invitingly clean appearance to the consumer. The
assembled cartridge is further easily cleanable between uses, for
example, by scrubbing and/or spraying with an aqueous-based
cleaning solution and then drying in any suitable manner.
[0071] The outer insulating case 30 includes a top section 32 that
is secured to a bottom section 34 in any suitable manner (e.g., via
a suitable adhesive, welding, etc.). The top section defines a
compartment that is suitably dimensioned to receive cartridge 4,
with an inner ledge 33 formed along the inner peripheral side wall
surfaces at an upper end of the case 30. The inner ledge 33 is
suitably dimensioned to engage and support the lip portions 7 and
21 of the top and bottom sections of cartridge 4 when the cartridge
is placed within the outer insulating case compartment. When the
cartridge is received within the outer insulating case, the raised
lip portion 7 of the cartridge is nearly flush or coplanar with the
top of the case. Alternatively, it is noted that the case can be
configured to receive any number of cartridges (e.g., two or more)
depending upon the requirements for a particular foodservice
application. In such an embodiment, the case would have a height
that is extended from the configuration shown in the figures to
accommodate multiple cartridges.
[0072] A removed portion 40 of the ledge 33 is defined along at
least one side of the case 30 at a location that is aligned and
corresponds with the cut-out portions 14, 24 of the cartridge 4.
Preferably, each side wall includes such a removed portion 40, so
as to facilitate placement of the cartridge within the outer
insulating case in any manner while ensuring that the cartridge
cut-out portions are aligned with a removed ledge portion of the
case. The removed portions 40 facilitate easy removal of the
cartridge from the outer insulating case by insertion of a user's
hand beneath the lip portions 7 and 21 of the cartridge in order to
obtain a better grip of the cartridge.
[0073] As can be seen in FIG. 5, each of the side walls of top
section 32 is folded over at the upper end of the top section so as
to form a double wall configuration. The double wall configuration
includes an outer wall member 35 defining an outer surface of the
case 30 and an inner wall member 36 that is separated a selected
distance from the outer wall member and is configured to engage at
least a portion of the cartridge outer wall when the cartridge is
placed within the compartment of the case. The distance between the
inner and outer wall members of the top section define a space or
air gap between the inner compartment walls and the outer walls of
the outer insulating case. The outer wall members 35 of the top
section 32 taper slightly in an outward direction from the top to
the bottom of the case 30, such that the cross-sectional dimensions
of the case are slightly larger at its bottom than at its top. As
described below, this feature facilitates the stacking of units on
top of each other in a foodservice environment to maximize
point-of-sale food placement while minimizing floor space.
[0074] The bottom section 34 of case 30 has a generally U-shaped
cross-sectional configuration, with a top wall 38 that is secured
to a bottom wall 37 of top section 32. The top wall 38 of bottom
section 34 extends beyond the top section bottom wall 37 to side
walls 39. The side walls 39 of the bottom section extend below top
wall 38 and are secured to lower portions of the outer side walls
35, thus defining a space or air gap between the bottom section top
wall and a surface which supports the outer insulating case 30.
Thus, the compartment walls of the outer insulating case are
separated from the outer walls of the case and the surface which
supports the case such that air gaps surround the sides and bottom
of the compartment.
[0075] The air gaps provide further insulation to the cartridge and
food items stored within the cup wells of the cartridge from the
ambient environment in which the unit is placed. The dimensions of
the air gaps between inner and outer walls of the top section as
well as between the bottom section top wall and support surface can
be modified in any suitable manner to provide the desired
insulating effect for a particular application. Preferably, the
distances between the inner and outer walls of the top section and
between the bottom section top wall and a support surface for the
unit are in the range of about 0.5 inch (1.3 cm) to about 1.5
inches (3.8 cm). In addition, any suitable insulation material
(e.g., foam, liquid, gel, etc.) can be provided in the air gaps as
desired to achieve the desired level of insulation for the
cartridge disposed within the outer insulating case.
[0076] The outer insulating case can have any suitable dimensions,
depending upon a particular foodservice application and the number
and/or types of food or beverage items that are to be thermally
treated. In an exemplary embodiment, the outer insulating case can
be square or rectangular and has outer length and width dimensions
ranging from about 18 inches (46 cm) to about 24 inches (61 cm),
and a height of about 4 inches (10 cm) to about 8 inches (20 cm),
so as to facilitate receipt of a cartridge that stores cups of
varying sizes (e.g., cup sizes from about 3 ounces or less to about
10 ounces or more). The cartridge and cover are dimensioned
appropriately to be assembled with the outer insulating case having
the dimensions noted above.
[0077] The outer insulation case can be constructed of any suitable
materials, such as polyethylene as noted above. In addition, the
top and bottom sections of the case can be constructed in any
suitable manner (e.g., via injection molding, extrusion, etc.).
Portions of the case are preferably constructed of a
light-reflecting material so as to minimize radiant heat transfer
within the unit due to light. In an exemplary embodiment, the outer
wall surfaces of top and bottom sections of the outer insulating
case are constructed of a suitable transparent plastic material,
while the surfaces of the top section inner walls are coated with a
reflective and/or electrostatically applied metallic substance
(e.g., a reflective paint or a thin strip or sheet of metal) so as
to impart a mirror-like finish to the outer surfaces. The
mirror-like finish further minimizes heat gain via radiant heat
within the outer insulating case compartment, and also provides a
modern and aesthetically pleasing appearance to consumers. The
outer walls of the outer insulating case can further include any
suitable indicia that contain descriptive information of the food
or beverage product within the unit and/or other aesthetic images
or features that are pleasing to consumers in a foodservice
environment.
[0078] The outer insulation case and/or the cartridge can further
include handles or any other suitable gripping surfaces to
facilitate easy lifting and transport of the unit to desired
locations. For example, as noted above, the cut-out section 24 of
the cartridge serves as a handle for transport of the cartridge
during periods of non-use with the outer insulating case. In
addition, the handles or gripping surfaces can be designed to
facilitate storage of the case and/or cartridge (e.g., by
suspending the case or cartridge from a hook or post on a wall
surface).
[0079] The cover 50 has a generally U-shaped cross-sectional
configuration and is suitably dimensioned to easily fit over the
top of case 30 so as to seal and insulate the compartment including
cartridge 4 from the ambient environment, thus minimizing or
preventing heat transfer into the unit. As noted above, the cover
can be constructed of any suitable materials, and the cover can
further be constructed via an injection molding process, an
extrusion process, or in any other suitable manner. The cover is
preferably constructed of a suitable transparent plastic material
to allow consumers to see through the cover to the food items
secured within the wells 10 of the cartridge 4 disposed within the
outer insulating case compartment.
[0080] While the cover depicted in FIG. 1 is a single piece, the
cover can have other suitable configurations. For example, the
cover can be constructed of two or more parts, where the cover
includes doors that are removably secured or attached via a hinge
or other connection to other portions of the cover.
[0081] In addition, as noted above, the outer wall members 35 of
the top section 32 taper slightly in an outward direction from the
top to the bottom of the case 30, such that the dimensions of the
case are slightly larger at its bottom than at its top. This
facilitates stacking of multiple cases 30 on top of each other as
shown in FIG. 6. Each case 30 in FIG. 6 includes a cartridge 4 that
is filled with food or beverage products (such as slush beverage
products in cups) disposed within the wells 10 of the cartridges.
The outer insulating case disposed at the top of the stack includes
a cover 50 placed thereon to insulate and isolate the food items
within this case from the ambient environment.
[0082] Each outer insulating case is preferably suitably
dimensioned to provide a lower end air gap of sufficient dimensions
(e.g., a distance ranging from about 0.5 inch (1.3 cm) to about 1.5
inches (3.8 cm) between the top surface 38 of the outer insulating
case bottom section 34 and a support surface) that renders a stable
supporting engagement for each successively stacked case, thus
preventing any case from being inadvertently pushed from any one or
more cases that are stacked below the case. The stacking of units
on top of each other in this manner maximizes point-of-sale food
placement while minimizing floor space in a foodservice
application. When all of the food items have been removed from the
cartridge of the top unit, this unit can be removed so as to expose
the next unit below, and the cover can then be placed on this next
unit.
[0083] The unit of the present invention can be used to thermally
treat food or beverage items in a number of different ways. For
example, when thermally treating slush beverages, the unit of the
present invention can be used to store and maintain the slush
beverage at desired temperatures and in a desirable partially
frozen state for extended time periods (e.g., time periods from
about 1 hour to about 6 hours or more). In addition to storing the
slush beverage product in this manner, the unit can also be used to
form the slush beverage product from a liquid that is chilled but
not in any frozen state by thermally treating the liquid in a
manner described below. Exemplary methods of operation for the unit
as depicted in the figures are described below for thermally
treating slush beverage products in a school cafeteria
environment.
[0084] Initially, cartridge 4 is cooled for a selected period of
time and at a selected temperature in a refrigeration unit or
freezer so as to achieve a sufficient temperature for the heat
transfer material within the cartridge and thus render the heat
transfer material as a suitable heat sink. In school cafeteria
operations, unit 2 is used during lunch periods. Prior to being
used each day, the cartridge 4 is cooled by storing it in a freezer
on a nightly basis (e.g., for a period of about 8-12 hours) and at
a suitable temperature such that the heat transfer material is in
the range of about 1.degree. F. (0.56.degree. C.) to about
10.degree. F. (5.6.degree. C.) below the desired temperature range
in which the food or beverage items are to be maintained during
operation of the unit. For slush beverage products, the heat
transfer material preferably has a phase change temperature in the
range of about 22.degree. F. (-5.6.degree. C.) to about 24.degree.
F. (-4.4.degree. C.), and the heat transfer material is preferably
a gel which is frozen in the freezer for the time periods noted
above and at a suitable temperature such that the heat transfer
material is in effect "charged" to its full heat transfer capacity
and is within this temperature range prior to removal of the
cartridge from the freezer.
[0085] Upon removal of the cartridge 4 from the freezer, the wells
10 of the cartridge are loaded with cups containing the slush
beverage cups. In one embodiment, the slush beverage is already
formed with a conventional slush beverage machine (e.g., any of the
types of slush beverage machines as described above) and poured
into cups, and the cups are then loaded into the wells of the
cartridge. In another embodiment described below, the cups
containing a chilled liquid are provided in the cartridge wells,
and the cartridge cools the liquid to form the slush beverage
product (thus eliminating the need for a slush beverage
machine).
[0086] The cartridge is then placed within the compartment of outer
insulating case 30, and a cover 50 is optionally placed on top of
case 30 to seal the cartridge within the case and minimize or
prevent air convection and heat transfer between the cartridge and
the ambient environment. The unit is lightweight and portable,
facilitating movement of the unit with relative ease to a
point-of-sale location for the unit, such as a school cafeteria
lunch line. Optionally, a number of cooled and "charged" cartridges
(i.e., cartridges with frozen gel material) can be placed in
corresponding cases 30 and then stacked in the manner depicted in
FIG. 6, with the uppermost case 30 being sealed with a cover 50,
where the stack is formed in the school lunch line.
[0087] During use of the unit, a consumer (e.g., a student) removes
cover 50 from the outer insulating case 30 and then removes a
desired number of cups containing slush beverage product from the
wells 10 of cartridge 4. Alternatively, the cover 50 can be removed
by a foodservice employee prior to use of the unit by consumers.
The grooved sections 12 allow the consumer to easily grasp a cup in
a well 10 with, for example, a thumb and finger. When a cartridge 4
is emptied of cups, the case 30 can be removed by a foodservice
employee for cleaning operations. If the units 2 are disposed in a
stack, the top case 30 is simply removed, thus exposing the next
case 30 disposed below the empty case to facilitate further
selection of slush beverage cups by consumers.
[0088] The unit design facilitates heat transfer between the slush
beverage product, through the walls of the wells 10, and the heat
transfer material disposed within an upper portion of the
cartridge, so as to maintain the slush beverage at the desired
temperature and partially frozen state. Further, the insulation
section 16 and outer insulating case 30 substantially minimize or
prevent heat transfer between the slush beverage produce disposed
within the cartridge wells and the surrounding environment. In a
stacked configuration, the top portion of each unit 2 is
effectively sealed from convective air flows in the surrounding
environment due to another unit 2 being stacked upon the top
portion of each unit or the cover 50 secured to the unit located at
the top of the stack.
[0089] A unit 2 that has been emptied of food or beverage items can
be easily cleaned and prepared for re-use (e.g., for school lunch
periods or other foodservice operations that are scheduled for the
next day) by removing the cartridge 4 from case 30. The cartridge
can be easily cleaned with water and/or a suitable cleaning
solution, wiped dry, and then loaded into the freezer for cooling
and "re-charging" of the heat transfer material within the
cartridge. The cartridge is cooled at a suitable temperature within
the freezer for a suitable period of time (e.g., about 8-12 hours),
and the cartridge is then ready for re-use in foodservice
operations.
[0090] The units 2 can further be used to convert a liquid beverage
product into a partially frozen slush beverage product and further
maintain the formed slush beverage product in its partially frozen
state for an extended period of time. This is a very useful
feature, particularly for school lunch cafeterias, since the
requirement for a slush beverage machine (which produces the slush
beverage product prior to loading the product within the units) is
now eliminated altogether.
[0091] An exemplary method for converting a liquid beverage product
into a partially frozen slush beverage product is now described.
Initially, it is noted that the liquid beverage product includes a
fruit juice that preferably has a freezing point within the range
of about 25.degree. F. (-3.9.degree. C.) to about 29.degree. F.
(-1.7.degree. C.). The slush beverage product is preferably
maintained within the freezing point temperature range of the fruit
juice in order to ensure that the slush beverage product has the
desired partially frozen state when served to consumers. With such
freezing point ranges, the heat transfer material preferably has a
phase change temperature in the range of about 22.degree. F.
(-5.6.degree. C.) to about 24.degree. F. (-4.4.degree. C.).
However, other beverages with different freezing points, including
non-juice beverages, may also be used, and the amount and phase
change temperature of the heat transfer material can be adjusted
based upon the freezing point of the beverage selected in order to
achieve the desired partially frozen slush beverage state.
[0092] Preferably, the liquid beverage includes a suitable
nucleating agent that serves to induce formation of ice crystals as
the liquid reaches its freezing point, and to further minimize or
prevent the potential for a phenomenon known as "supercooling" by
which a liquid reaches a temperature below its freezing point
without freezing. Supercooling can occur at temperatures as much as
10.degree. F. (5.6.degree. C.), or more, below the freezing point,
and often occurs more readily when liquids are quiescently frozen
(e.g., as in the method described herein). Any suitable nucleating
agent that is also suitable for use as an additive in food and
beverage products can be provided including, without limitation,
alkaline salts such as chlorides and carbonates. Preferably,
calcium carbonate is provided in the juice as the nucleating agent
in an amount of between about 0.1% to about 0.2% by weight (e.g.,
about 0.15% by weight). The actual amount of nucleating agent will
depend on the freezing point and other characteristics of the fruit
juice used. The use of calcium carbonate as a nucleating agent in
the amounts described above provides certain additional advantages
during the formation of the partially frozen slush beverage in the
cartridge, in particular to the formation of a relatively uniform
dispersion of ice crystals, where the ice crystals are of a
relatively small size.
[0093] In an embodiment where the beverage product is a milkshake,
the milkshake preferably includes iota carageenan, which imparts an
enhanced texture or "mouth feel" and also inhibits the separation
of ingredients. The preferred amount of iota carageenan provided in
the milkshake is from about 0.01% to about 0.05% by weight, most
preferably about 0.025% by weight. The milkshake also preferably
includes mono- and/or diglycerides to provide emulsification,
thereby binding water and fat to prevent separation. The preferred
amount of mono- and/or diglycerides provided in the milkshake is
from about 0.08% to about 0.15% by weight, most preferably about
0.12% by weight. The milkshake also preferably includes polysorbate
80 to further the incorporation of air into the product, impart a
dry surface appearance to the product, and improve the extrusion of
the product from a batch or continuous freezer. The preferred
amount of polysorbate 80 provided in the milkshake is from about
0.02% to 0.08% by weight, most preferably about 0.06% by weight.
The milkshake also preferably includes microcrystalline cellulose
("cellulose gel") to impart a fuller and more pleasing texture and
"mouth feel" if the milkshake is a reduced fat, lowfat or nonfat
product, and to further the retention of air cells dispersed
throughout the product during tempering and holding in the unit.
The preferred amount of cellulose gel in the milkshake is from
about 0.1% to about 0.5% by weight, most preferably about 0.15% by
weight. The milkshake also preferably includes locust bean gum
(also known as "carob bean gum") to retard melting of the product,
inhibit separation of water from the other ingredients in the
product, and improve extrusion from the continuous or batch
freezer. The preferred amount of locust bean gum in the milkshake
is from about 0.05% to 0.25% by weight, most preferably about 0.10%
by weight.
[0094] The additives described above work with milkshakes sweetened
only with nutritive sweeteners (e.g., sucrose, corn syrup or other
nutritive sweeteners), as well as with milkshakes sweetened in
whole or in part with artificially sweeteners (e.g., sucralose,
aspartame, or other artificial sweeteners). In a preferred
embodiment, the milkshake is sweetened with a combination of
sucrose, corn syrup and sucralose.
[0095] A preferred embodiment of a fruit juice to be converted to a
slush beverage product includes a blend of stabilizers, including
carboxymethycellulose ("cellulose gum") and locust bean gum. The
preferable amount of the cellulose gum in the fruit juice is from
about 0.1% to about 0.5% by weight, most preferably about 0.15% by
weight. The preferable amount of locust bean gum in the fruit juice
is from about 0.05% to about 0.25% by weight, most preferably about
0.08% by weight. Cellulose gum and locust bean gum are provided in
the juice to serve as stabilizers for inhibiting the formation of
objectionably large ice crystals in the slush beverage product. The
locust bean gum also serves to improve extrusion from a continuous
or batch freezer, to support a relatively uniform dispersion of the
nucleating agent and to reduce the tendency of the nucleating agent
to settle to the bottom of the beverage product. This in turn
permits the nucleating agent to induce ice crystal formation
relatively uniformly throughout the juice beverage rather than
initially just at the bottom of the cup containing the juice
beverage.
[0096] Various other proportions of pectin, xantham and locust bean
gum can also be utilized in accordance with the invention. In
addition, other stabilizers and polysaccharide gums can be used
that are acceptable for food grade applications including, without
limitation, carboxymethyl cellulose (cellulose gum),
microcrystalline cellulose (cellulose gel), guar gum, carageenan,
as well as other conventional food grade stabilizers and gums.
[0097] The fruit juice beverage is first poured into a selected
number of cups that are suitably dimensioned and configured for
placement within the cup wells 10 of unit cartridges 4. For
example, the cups may be filled with fruit juice at a supplier's
plant by any conventional process, and then frozen for shipment.
Alternatively, the cups may be filled aseptically or by a
conventional process known as "hot fill" in order to render the
juice bacteriologically stable for an extended period without
refrigeration.
[0098] If the fruit juice is received from a supplier in a frozen
state, the cups are placed into a commercial cooler for thawing.
Thawing typically requires one to two days. Once thawed, the cups
remain in the cooler pre-chilled, as described below, prior to
being removed for service. The supplier would typically inform the
foodservice operation of the period of time by which the cups, once
chilled, should be used.
[0099] If the cups are received from the supplier in a
"shelf-stable" state, the cups may be stored at room temperature
for a period not to exceed the "use by" date stamped on the cups
(typically a period of 6 to 12 months from manufacture). Prior to
use, the cups should be pre-chilled in the manner described below
prior to being placed in service.
[0100] The cups containing the fruit juice beverage are preferably
pre-chilled to a selected temperature range and for a suitable time
period prior to being placed or loaded within the cartridge wells
to initiate the partial freezing and formation of slush beverage
product. The temperature at which the fruit juice is pre-chilled
will depend upon the composition of the fruit juice, but the
temperature is preferably above the point at which formation of ice
crystals within the fruit juice is initiated. An exemplary
temperature range for pre-chilling the fruit juice is from about
35.degree. F. (1.7.degree. C.) to about 42.degree. F. (5.6.degree.
C.).
[0101] Upon achieving the desired temperature of the fruit juice
beverage from pre-chilling the cups at the suitable temperature
range, the fruit juice cups are loaded into one or more cartridges
4. Prior to loading the cartridges with cups, the cartridges have
been chilled in a freezer in the manner described above so that the
heat transfer material within the cartridges has achieved a desired
temperature (i.e., the heat transfer material is "charged") and is
ready for effectively chilling the fruit beverage.
[0102] The unique design of the units 2 described above facilitates
the transformation of the fruit juice into a slush beverage product
having a desirable partially frozen state in a period of about 1-2
hours. Thus, the foodservice employee loads the cartridges 4 with
the pre-chilled fruit juice cups and places the cartridges into the
outer insulating cases 30, and optionally stacks the cases, in the
manner described above at a suitable time period (e.g., at least
about 1 hour) prior to the first lunch hour or other foodservice
function. After the slush beverage product is formed within the
cartridges, the units maintain the slush beverage product in the
cup wells at a suitable temperature and in a desirable partially
frozen state for an extended time period (e.g., for a period of up
to about 4 hours or more).
[0103] As noted above, the cartridge of the unit can include an
insulating section (preferably a closed cell foam material) with a
heat transfer material (preferably a gel material with a selected
phase change temperature). Alternatively, the cartridge may include
no insulating section, such that the cartridge can be filled
partially or entirely with heat transfer material. Further still,
in embodiments where it is desirable to insulate a food or beverage
item without the feature of providing significant heat transfer
between the cartridge and the food or beverage item, the cartridge
can be provided with no heat transfer material, such that the
internal cartridge volume is partially or entirely filled with the
insulation section.
[0104] In another embodiment of the present invention, a portable
thermal treatment and storage unit includes one or more vents or
ports on the unit that are selectively opened or closed to
facilitate a controlled flow of air through the unit to thermally
treat food or beverage products loaded within the unit. For
example, this unique design for the unit facilitates tempering or
controlled warming and at least partial thawing of frozen or
partially frozen beverage products that have been loaded into the
unit and warmed to achieve a desirable partially frozen slush
beverage state by permitting selective airflow through the unit.
After a select time period, the ports of the units can be closed
such that the unit insulates and maintains the slush beverage
products in their partially frozen state for a selected time
period. This unit is particularly useful for converting frozen food
or beverage items into partially frozen products, such as slush
beverage products and partially frozen dairy products (e.g., hard
or soft ice cream, milk shakes, etc.). However, the unit is not
limited to treating these types of items, but rather can also be
used to thermally treat a wide variety of other food or beverage
items including, without limitation: frozen yogurt, sherbet, ice
milk, jellos, puddings and fruit cups; partially frozen, frozen or
liquid juices, including juices packaged in cups and flexible
pouches; fruit-flavored confections commonly referred to as
"Italian Ice;" and popsicles, as well as other formed and shaped
confections, including sherbet and frozen juice products packaged
in tetrahedron shaped packets.
[0105] An exemplary embodiment of such a thermal treatment and
storage unit is depicted in FIGS. 7-11. In particular, unit 100
includes a hollow and generally rectangular housing 102 including
an open top end, first and second opposing side walls 103, 104,
third and fourth opposing side walls 105, 106 and a bottom wall 107
that define a chamber 108 within the housing. The first and second
opposing side walls 103, 104 have a larger lengthwise dimension
than the third and fourth opposing side walls 105, 106, and the
unit is designed such that the third side wall 105 forms a front
end of the unit while the fourth side wall 106 forms a rear end of
the unit. While the housing depicted in the figures is generally
rectangular, it is noted that the invention is not limited to such
a geometric configuration but rather can include any other suitable
configurations including, without limitation, square, round, oval,
eccentric, multi-faceted, etc.
[0106] The housing as well as other portions of the unit 100 can be
constructed of any one or more types of materials that are suitable
for being used and re-used in multiple applications for thermally
treating food or beverage items, where the materials preferably
have suitable insulating properties, are lightweight, durable,
easily cleanable, and are moisture resistant or non-absorbent so as
to not degrade upon contact with water or other liquids. For
example, the housing and other portions of the unit can be
constructed of a cardboard material that is covered or coated with
a non-absorbent or moisture resistant coating (e.g., a polymethyl
methacrylate coating such as the type commercially available under
the trademark LEXAN, or a polyester film such as the type
commercially available under the trademark MYLAR). Alternatively,
the housing and other portions of the unit can be constructed of
any one or more suitable polymer or plastic materials including,
without limitation, polyethylene, polypropylene, and high impact
styrene materials such as acrylonitrile butadiene styrene
(ABS).
[0107] In addition, the outer surfaces of the housing side walls
can be coated with a reflective and/or electrostatically applied
metallic substance (e.g., a reflective paint or a thin strip or
sheet of metal) so as to impart a mirror-like finish to the outer
surfaces so as to minimize heat gain via radiant heat within the
outer insulating case compartment. The mirror-like finish also
provides a modern and aesthetically pleasing appearance to
consumers. The outer side walls of the housing can further include
any suitable indicia that contain descriptive information of the
food or beverage product within the unit and/or other aesthetic
images or features that are pleasing to consumers in a foodservice
environment.
[0108] The first and second side walls 103, 104 of the housing 102
further include a series of cut-out sections that form vents or
ports which provide a flow path for air between the housing chamber
108 and the surrounding environment in which the unit is placed. As
described below, these ports can be selectively opened and closed
to facilitate airflow through the housing. Referring to FIG. 7,
each of the first and second side walls 103, 104 includes three
cut-out sections or ports 110 that are generally evenly spaced from
each other along a lower surface of the side wall (e.g., within
about one inch or about 2.54 cm from the bottom end of each side
wall). The ports have a generally rectangular configuration and
they also have similar dimensions. However, it is noted that the
dimensions and geometric configurations of any two or more ports
can differ. Further, it is noted that the first and second side
walls can include any suitable number of vents or ports (e.g., one
or more), and the unit can also be designed such that any side
walls (e.g., first, second third, fourth and/or bottom side walls)
can include vents or ports to facilitate flow of air through the
housing in the manner described below.
[0109] The unit 100 includes a cup holder 125 that is securable
within the housing chamber 108 by insertion at the top end of
housing 102 to seal the housing chamber and support cups at a top
wall 126 of the cup holder. The cup holder 125 includes opposing
first and second side walls 128, 129 and opposing third and fourth
side walls 130, 131 that extend from the top surface 126. The top
wall 126, and side walls 128-131 are suitably dimensioned such
that, upon full insertion of the cup holder 125 within the housing
chamber 108, the first and second side walls 128,129 of the cup
holder correspond and engage with the first and second side walls
103, 104 of the housing, while the third and fourth side walls 130,
131 of the cup holder correspond and engage with the third and
fourth side walls 105, 106 of the housing.
[0110] When the cup holder is fully inserted and assembled within
the housing chamber 108, the ends of the side walls 128-131 of the
cup holder engage with the bottom end 107 of the housing and the
top wall 126 closes the housing chamber and is generally flush with
the top end of the housing. The first and second side walls 128,
129 of the cup holder further include three cut-out sections or
ports 132 that are aligned and correspond with the ports 110 of the
housing when the cup holder is assembled within the housing so as
to provide an airflow path between the housing chamber 108 and the
surrounding environment when the cup holder is fully assembled
within the housing chamber.
[0111] The side walls of the cup holder combine with the side walls
of the housing to provide a double side wall configuration for the
unit when the cup holder is assembled within the housing. This
double side wall configuration increases the side wall material
thickness and enhances the insulation for the unit to prevent or
substantially minimize heat transfer between the housing chamber
and the environment surrounding the unit. However, it is noted
that, rather than providing side walls for the cup holder that fit
within and correspond with the side walls of the housing, the cup
holder can alternatively be configured as a cover with side walls
that fit around the top end of the housing. Further, the cup holder
can be formed as an integral or attached part of the housing (e.g.,
as a top wall of the housing).
[0112] The top wall 126 of the cup holder 125 includes a series of
generally circular openings 134 that extend through the top wall to
facilitate communication with the housing chamber 108. In addition,
a generally rectangular insert 136 is secured to an underside
surface of the cup holder top wall 125 (e.g., via an adhesive), and
the insert includes openings 138 that extend through the insert and
correspond with the openings 134 of the top wall to permit access
to the housing chamber 108 when the cup holder is assembled with
the housing. The insert is preferably constructed of a suitable
insulation material to effectively prevent or substantially limit
heat transfer through such material. For example, the insert can be
constructed of a suitable closed cell foam material (e.g., a closed
cell polyethylene material) and/or any other suitable lightweight
insulating polymers or plastic materials. The insulating insert can
have a thickness in the range of about 0.5 inch (1.27 cm) to about
1.5 inches (3.81 cm). Preferably, the insulating insert has a
thickness of about 1 inch (2.54 cm).
[0113] Referring to FIGS. 10 and 11, the cup holder top wall and
insert openings 134 and 138 are arranged in generally linear rows
and columns along the top wall 126. The top wall openings are
further suitably dimensioned to receive and retain a food or
beverage cup of any selected size (e.g., 5 or 10 ounce cups), such
as a cup 150 with a slightly tapered cylindrical or frustum-like
configuration as depicted in FIG. 11 (where the cup diameter
decreases from the top to the bottom of the cup) and that is
slightly tapered in diameter from a top surface to a bottom surface
of the beverage cup. In particular, each opening 134, 138 is
suitably dimensioned to receive a substantial portion of a cup 150
(i.e., a majority of the volume of the cup) within the housing
chamber 108, while the cup holder top wall 126 supports the cup at
an upper portion of the cup such that a cup lid 152 remains exposed
outside of the housing chamber. The openings can be arranged in any
selected pattern along the top wall of the cup holder. In addition,
while the unit 100 of FIGS. 7-11 is depicted with twelve openings
to receive and retain twelve cups of food or beverage product, it
is noted that the unit can include any selected number of openings
to facilitate thermal treatment of the same number of cups for a
particular application.
[0114] Each of the top wall and insulating insert further includes
cut-out groove sections 140, 142 that extend through the top wall
and insert so as to provide an airflow path between the housing
chamber 108 and the environment surrounding the unit. The groove
sections 140, 142 extend in a radial direction from the openings
134, 138, with each opening including four groove sections spaced
at generally equal angularly spaced distances (i.e., about
90.degree.) from each other so as to form an "X" configuration
around the opening. However, it is noted that the unit can be
designed with openings including any selected number of groove
sections (e.g., one or more) that are at any selected angular
spaced orientations with respect to each other.
[0115] As in the previous embodiment described above and depicted
in FIGS. 1-5, the groove sections 140, 142 facilitate easy removal
of a cup from the unit 100 by a user without unseating the cup lid.
In particular, the user can insert a thumb and forefinger into a
pair of diametrically opposed groove sections 140, 142 adjacent a
particular opening 134, 138 to facilitate easy removal of the cup
disposed within the cup holder 125. The multiple groove sections
further facilitate easy access and removal of the cup from the cup
holder by the user using a left or right hand. Further, the groove
sections 140, 142 provide a vent or port for facilitating airflow
through the housing during use of the unit in the manner described
below.
[0116] The unit 100 further includes a generally rectangular
movable member 115 that is suitably dimensioned to be received
within chamber housing 108 so as to engage with the bottom wall 107
of the housing. The movable member 115 has a lengthwise dimension
that is smaller than the lengthwise dimension of the housing such
that, upon placement of the movable member within the housing
chamber 108, the movable member is movable by sliding along an
interior surface of the bottom wall 107 in a lengthwise direction
toward and away from each of the third side wall 105 (or front end)
and the fourth side wall 106 (or rear end) of the housing. In
addition, the width dimension of the movable member 115 (i.e., the
dimension that is transverse its lengthwise dimension) is slightly
smaller than the width dimensions of the housing and the cup holder
(i.e., the dimension between first and second side walls 103, 104
of the housing and the first and second side walls 128, 129 of the
cup holder) such that side wall portions of the movable member
engage and slide along the corresponding interior wall surfaces of
the first and second housing walls 128, 129 of the cup holder
assembled within the housing during sliding movement of the movable
member within the housing.
[0117] Preferably, the movable member is constructed of a suitable
insulation material to effectively prevent or substantially limit
heat transfer through the movable member. For example, like the
insulation insert of the cup holder, the movable member can be
constructed of a suitable closed cell foam material (e.g., a closed
cell polyethylene material) and/or any other suitable lightweight
insulating polymers or plastic materials.
[0118] The movable member has a sufficient thickness to close or
cover the ports 110, 132 of the first and second side walls 103,
104, 128, 129 of both the housing and the cup holder when the
movable member is disposed and oriented in a suitable manner within
the housing chamber 108 as described below. For example, the
movable member can have a thickness in the range of about 0.5 inch
(1.27 cm) to about 1.5 inches (3.81 cm). Preferably, the movable
member has a thickness of about 1 inch (2.54 cm). The ports 110 and
132 are also suitably dimensioned and disposed along lower surface
portions of the first and second housing side walls such that the
ports do not extend above an upper end of the movable member
disposed within the housing.
[0119] The housing, movable member and cup holder are further
suitably dimensioned to receive any selected number of food or
beverage cups of any selected sizes and volumetric dimensions such
that the cups are supported by the top wall 126 of the cup holder
and are further suspended within the housing chamber a suitable
distance from the movable member 115 as depicted in FIG. 11. For
example, the dimensions of the housing, movable member and cup
holder can be selected such that distance between the bottom of
each cup secured by the cup holder is no greater than about 1 inch
(2.54 cm), preferably no greater than about 0.5 inch (1.27 cm), and
more preferably no greater than about 0.25 inch (0.635 cm). The
distance maintained between each cup and the movable member
provides an air gap within the housing chamber that permits the
flow of air around each cup bottom during thermal treatment of the
beverage cups in the manner described below.
[0120] The two opposing side walls of the movable member 115 that
correspond and engage with the first and second side walls 128, 129
of the cup holder 125 include three cut-out sections 116. The
cut-out sections 116 are suitably dimensioned and oriented along
the movable member side walls so as to correspond and align with
the ports 110, 132 of the housing and cup holder when the movable
member is positioned within the housing chamber 108 as depicted in
FIG. 8A, where a rear end 118 of the movable member is adjacent the
fourth side wall 131 (i.e., at the housing rear end) of the cup
holder assembled within the housing. In this position, a front end
117 of the movable member is distanced from the front end of the
housing.
[0121] The rear end 118 of the movable member 115 includes a tab
120 that extends at about a central location from this rear end.
Tab 120 is suitably dimensioned and aligned with openings 112, 135
disposed at a lower location along the fourth or rear end walls
106, 131 of the housing 102 and the cup holder 125 so as to extend
a sufficient distance through the openings when the movable member
is positioned with its rear end 118 adjacent the interior surface
of the fourth side wall 131 of the cup holder. Sliding of the
movable member 115 within the housing chamber 108 from its
orientation as depicted in FIG. 8A to its orientation as depicted
in FIG. 8B is facilitated by an operator grasping and pushing tab
120 into the housing chamber 108 such that the movable member moves
toward the housing front end.
[0122] When the movable member is fully displaced within the
housing chamber (as depicted in FIG. 8B) such that its front end
117 is adjacent the interior surface of the side wall 130 of the
cup holder (i.e., at the housing front end), the cut-out sections
116 of the movable member are shifted out of alignment with the
housing ports 110, 132. In this fully displaced configuration, the
side wall surface portions of the movable member located adjacent
the cut-out sections 116 are aligned with and close or seal the
housing ports 110, 134 from airflow communication with the housing
chamber 108. The tab 120 can also be pulled through openings 112,
135 and away from the housing front end so as to fully displace the
movable member from the position depicted in FIG. 8B back to its
position in FIG. 8A, where the cut-out sections 116 are once again
aligned with ports 110, 132 to facilitate communication of the
ports with the housing chamber 108.
[0123] The unit 100 described above is effective in thermally
treating and storing food and/or beverage products at desired
temperatures and in desired states for extended periods of time
(e.g., about 2-4 hours or more) and without any electrical energy
requirements. In addition, unlike the previous embodiment of FIGS.
1-5, this unit does not require any initial "charging" or thermal
treatment prior to being used.
[0124] As in the previous embodiment, the components of the unit
can be suitably dimensioned to accommodate any suitable number of
cups (or other food and/or beverage containers) of any suitable
shapes and sizes depending upon a particular application. For
example, the unit can be suitably configured to receive cups in a
variety of different sizes including, without limitation, 3 ounce
cups, 4 ounce cups, 5 ounce cups, 6 ounce cups, 8 ounce cups, 10
ounce cups, 11 ounce cups, and 12 ounce cups. Exemplary units for
slush beverage products or partially frozen dairy products (e.g.,
soft serve ice cream, milk shakes, etc.) are designed to thermally
treat 5 once and 10 ounce cups of product.
[0125] An exemplary method for using the unit 100 of FIGS. 7-11 is
described below. In this method, a food or beverage product is
initially frozen prior to being loaded within the unit, and then
the food or beverage product is at least partially thawed for a
selected period of time by opening the ports (by manipulating the
movable member) disposed at the lower level of the housing and cup
holder to facilitate the flow of air currents from the ambient
environment through the housing. After a select time period in
which the frozen food or beverage is converted to a partially
frozen food or beverage product having a desired partially frozen
consistency, the ports are closed (by manipulating the movable
member) to prevent or substantially limit airflow through the
housing. The unit then maintains the beverage product at a desired
temperature and the desired and aesthetically pleasing partially
frozen consistency for a select period of time.
[0126] The frozen food or beverage product can be any selected type
of product including, without limitation, juice beverages and dairy
products (e.g., hard or soft ice cream, milk shakes, etc.). The
frozen product can further include alcohol and/or any other
selected flavor enhancing additives. The frozen product is also
preferably formed from a liquid, semi-liquid or gel product that
includes one or more suitable stabilizers and/or nucleating agents
such as the types noted above (e.g., any one or combination of
pectin, xantham gum, locust bean gum, guar gum, cellulose gum or
gel, carrageenan, and/or any other conventional food grade and/or
GRAS stabilizers and gums) in any suitable weight percentage ratios
depending upon a particular application, where the stabilizers
and/or nucleating agents limit the formation and size of ice
crystals so as to achieve a desired partially or semi-frozen
consistency that provides a desirable look, feel and texture to
consumers of the product.
[0127] The frozen food or beverage product can be prepared in the
following manner prior to being thermally treated by the unit 100.
The product is initially rapidly frozen in a continuous or batch
type freezing apparatus, such as a batch or continuous freezer that
is conventionally used in freezing dairy products (e.g., ice cream
products). The use of such a rapid freezing process and associated
batch or continuous equipment, together with the use of appropriate
stabilizers and/or nucleating agents in the product, ensures the
formation of small ice crystals and inhibits the growth of larger
ice crystals in the frozen beverage product, while allowing the
incorporation of air into the product, through rapid whipping, to
whatever level of "overrun" is best suited to the product being
produced. Preferably, the "fill level" of the product packaged at
the factory is such that, if packaged in cups, no product is in
contact with the lid of the cups. This intentional underfill (which
is a departure from conventional practice but is acceptable
provided the appropriate declarations as to contents are made on
the package label), creates a thin gap or layer of air between the
uppermost surface of the product within the cup and the underside
of the lid.
[0128] This gap or layer of air provided within a sealed cup
including the food or beverage product provides effective
insulation, when the cup is eventually placed in the unit, against
a rapid gain of heat into the product resulting from ambient air
being in contact with the lid which is in turn in direct contact
with the uppermost surface of the product in the cup. Such heat
gain would result in an undesirable rapid melting of the uppermost
surface of the product. The presence of an air gap furthers a
uniform tempering of the entire product within the cup. Preferably,
the air gap within each sealed cup has a thickness in the range
from about 0.25 (0.635 cm) inch to about 0.5 inch (1.27 cm), most
preferably about 0.375 inch (0.953 cm).
[0129] Once packaged at the factory, the product is frozen to a
temperature of from about 10.degree. F. (-12.2.degree. C.) to about
-40.degree. F. (-40.degree. C.). For example, for juices used to
form slush beverage products, the beverage product is preferably
initially frozen to a temperature of from about 10.degree. F.
(-12.2.degree. C.) to about 0.degree. F. (-17.8.degree. C.),
whereas dairy products (e.g., ice creams, milk shakes, etc.) that
are used to form soft serve partially frozen products are
preferably initially frozen to a temperature of from about
-30.degree. F. (-34.4.degree. C.) to about -40.degree. F.
(-40.degree. C.). The packaged frozen product (e.g., frozen product
in enclosed cups with covers or lids) is distributed in the frozen
state and at such frozen temperatures from a manufacture location
to an on-site location for use of the product and is further
maintained at such frozen state and frozen temperatures prior to
loading within the unit 100. The unit 100 is easily assembled by
insertion of movable member 115 within the housing chamber 108 such
that tab 120 extends through opening 112. The side walls 128, 129,
130, 131 of the cup holder 125 are then inserted within the housing
chamber 108, with the first and second side walls 128, 129 fitting
between the first and second side walls 103, 104 of the housing 102
and the corresponding side wall sections of the movable member 115
and the opening 135 on the rear end wall 131 of the cup holder
fitting over movable member tab 120.
[0130] Cups 150 of the frozen food or beverage product, which have
been frozen and stored in the manner described above, are loaded
into the unit by placing the cups through the openings 134, 138 of
the cup holder 125 such that a top portion of the cups (including
cup lids 152) are held by the top wall 136 and are further
suspended a selected distance (e.g., about 0.25 inch or greater,
see FIG. 11) from the movable member 115. The operator of the unit
ensures that the ports 110, 132 of the unit are open by pulling tab
120 such that the movable member is completely displaced toward the
housing rear end (as depicted in FIGS. 8A and 9A). In this open
port position, convective air flow currents are enabled through the
housing (e.g., as indicated by the arrows in FIG. 9A). In
particular, air that is at a higher temperature than the frozen
product in the cups flows into the housing chamber 108 (e.g., via
the groove sections 140, 142 as indicated by the arrows in FIG. 9A)
and around the cups 150 (including the bottom surfaces of the
cups), and then out of the housing (e.g., via ports 110, 132 as
indicated by the arrows in FIG. 9A). The air that flows through the
housing can be at ambient or room temperature, e.g., at a
temperature within the range of about 68.degree. F. (20.degree. C.)
to about 85.degree. F. (29.degree. C.). However, it is noted that
the temperature of the air flowing through the unit can be higher
or lower than this temperature range depending upon a particular
application.
[0131] The configuration and design of unit 100 facilitates an
effective and controlled warming or thawing of the frozen product
in a substantially uniform manner about the cups by the warmer
convective air currents flowing through the housing chamber so as
to convert the frozen product into a desirable partially frozen
product over a selected time period. For example, a frozen juice
product can be converted to a partially frozen slush beverage
product utilizing unit 100, where the slush beverage product has
the same partially frozen consistency as if the slush product were
produced by a conventional slush machine. In addition, a frozen
dairy (e.g., ice cream or frozen milkshake) product can be
converted to a partially frozen product having a desirable and
aesthetically pleasing semi-frozen milkshake or soft serve feel and
texture using unit 100.
[0132] An exemplary time period for converting the frozen product
into a desirable partially frozen product for serving to consumers
is no more than about 3 hours (e.g., 2 hours or less). This partial
thawing or warming time period can vary based upon a particular
application and the type of food or beverage product being
thermally treated. For example, at the end of the warming time
period, a frozen fruit beverage product can be converted from its
frozen state in the temperature range from about 10.degree. F.
(-12.2.degree. C.) to about 0.degree. F. (-17.8.degree. C.) to a
partially frozen slush beverage product at a temperature from about
20.degree. F. (-6.7.degree. C.) to about 27.degree. F. (about
-2.8.degree. C.).
[0133] Once the frozen product has sufficiently thawed in a
controlled manner to form a partially frozen product within the
unit 100, the operator closes ports 110, 132 by pushing tab 120 so
as to move the movable member 115 toward the housing front end
until the front end 117 is adjacent the interior surface of the
side wall 130 of the cup holder (as depicted in FIGS. 8B and 9B).
The closure of ports 110, 132 effectively substantially limits or
prevents convective air flow currents through the housing 102. In
this mode of operation, the unit 100 effectively insulates and
maintains the partially frozen food or beverage product at a
desired temperature or within a desired temperature range. For
example, for slush beverage products, the product temperature can
be maintained at about 20.degree. F. (-6.7.degree. C.) to about
25.degree. F. (-2.8.degree. C.) for a period of at least about 2
hours, where the slush beverage product exhibits only a slight
increase in temperature of about 1.5.degree. F.-2.degree. F.
(0.83.degree. C.-1.1.degree. C.) over such time period. Thus, the
slush beverage products can be maintained within a temperature
range of about 20.degree. F. to about 27.degree. F. during the
storage period of at least about two hours within the unit.
[0134] The partially frozen product is ready for consumption by a
consumer after the ports have been closed. The consumer simply
removes a cup 150 from a cup holder opening 134 (e.g., by inserting
a thumb and forefinger into grooves 140). In certain embodiments,
instructions may be provided on the cup that the user slightly
displace or shake the contents in the cup prior to serving.
[0135] The insulating properties of the unit 100 effectively
control the product temperature as does the cooled air that remains
within the unit. In particular, when the ports are open to
facilitate a convective flow of air through the housing which warms
and partially thaws the frozen product, the temperature within the
chamber due to heat transfer between the flowing air and the frozen
product can achieve a temperature in the range of about 38.degree.
F. (3.3.degree. C.) to about 50.degree. F. (10.degree. C.), and
more preferably no greater than about 40.degree. F. (4.4.degree.
C.). When the ports are closed so as to prevent or substantially
limit airflow through the housing, the stagnant air that remains
within the housing chamber can further cool (due to heat transfer
with the partially frozen product) to about 38.degree. F.
(3.3.degree. C.) or less, shortly after closing the ports.
Thereafter, the temperature of the air within the housing chamber
will gradually rise as cups are removed by consumers. This stagnant
air within the housing chamber further enhances the insulating
effect of the unit so as to minimize or substantially prevent heat
transfer between the partially frozen product and the ambient
environment surrounding the unit for a select time period (e.g., at
least about 2 hours).
[0136] The unit can further be designed to include operating
instructions at the housing rear end (i.e., side wall 106) to
advise the operator to initially open the ports (by pulling tab
120) after loading the product into the unit and to maintain the
ports in the open position for a selected period of time (e.g.,
about 2 hours) to achieve an effective warming and thawing of the
frozen product, and after such time the product is ready for
consumption (e.g., in a school cafeteria environment). After the
warming period, the instructions can advise the operator to close
the ports (by pushing tab 120) to switch the unit into an
insulating and storage mode for maintaining the partially frozen
product at a desired temperature and consistency that is desirable
for consumption. In addition, the unit can include an electronic
timer with a suitable audio and/or visual indicator (e.g., an LED
display) to indicate when the warming time period has expired and
the operator should close the ports.
[0137] When the unit is no longer being used and is taken out of
service, the unit can be disassembled and the components can be
cleaned. The unit can then be brought back into service and re-used
for any selected number of food service operations, without any
electrical energy requirements or the requirement of thermally
treating any portions of the unit prior to being used.
[0138] The thermal treatment unit described in FIGS. 7-11 can be
modified in any suitable manner to achieve the same warming/thawing
and insulation modes of operation as described above. For example,
any one or more ports can be disposed at any one or more selected
locations anywhere along the housing (e.g., top, bottom and/or mid
portions of the housing) to facilitate convective air flow through
the housing chamber. In one exemplary embodiment, one or more ports
can be disposed along the bottom wall of the housing and the unit
can be raised above a supporting surface to facilitate opening of
the ports for air flow through the housing. Closing of the ports
can be achieved by simply placing the unit on a supporting surface
so as to seal the ports from the ambient air surrounding the
unit.
[0139] In addition, the unit can be designed such that the ports
can be selectively opened or closed in any suitable manner. For
example, rather than utilizing a tab that extends through a rear
housing end wall to move the movable member as depicted in the
embodiment of FIGS. 7-11, an elongated opening can be provided
along the housing bottom wall, and the movable member can include a
corresponding finger engaging groove to facilitate movement of the
movable member toward the front and rear ends of the housing to
facilitate opening and closing of the ports as in the embodiment
described above.
[0140] Alternatively, rather than providing a movable member as
described in the embodiment above, the ports can be provided with
access doors that are movable in any suitable manner (e.g., via
hinges, a sliding door or other mechanism, etc.) to selectively
open and close the ports during operation of the unit. Thus, the
invention encompasses any suitable mechanism or structure that
facilitates selective opening of vents or ports within a thermal
treatment unit to permit warming and thawing of the frozen product
via convective air flow through the unit housing and also selective
closing of the vents or ports to limit or prevent air flow through
the unit housing while insulating and maintaining the product at a
desired temperature.
[0141] The thermal treatment unit described above and depicted in
FIGS. 7-11 can further be designed to be stackable in a similar
manner as the unit described above and depicted in FIGS. 1-6. The
stackable feature facilitates the placement of a large quantity or
volume of food and beverage product at a particular point-of-sale
location while minimizing floor space required for displaying such
product.
[0142] In addition, the thermal treatment unit of FIGS. 7-11 can
include a cover or lid of similar design to the lid described in
the embodiment of FIGS. 1-6. The cover can be designed to fit over
the cup holder of the unit and include one or more openings aligned
and in communication with one or more of the finger engaging groove
sections of the cup holder so as to facilitate flow of air through
the cover and the unit when the vents or ports of the housing are
open.
[0143] Another exemplary embodiment of a thermal treatment unit
provided in accordance with the invention is depicted in FIGS.
12-14. In particular, a thermal treatment unit and corresponding
method are provided for tempering (i.e., controlled warming) or
thawing of frozen beverage products, such as slush beverage
products or frozen products (e.g., milk shakes), in a controlled
and uniform manner so as to form a partially frozen beverage
product for consumption. The slush or dairy products can be of any
suitable types and compositions, such as the compositions described
above. In this embodiment, the thawing of the frozen beverage
products is achieved by placing the unit loaded with the frozen
beverage products in a refrigeration unit that provides an ambient
or surrounding temperature around the unit in a range from about
35.degree. F. (1.67.degree. C.) to about 41.degree. F. (5.degree.
C.). The unit is designed to facilitate controlled and
substantially uniform airflow to the frozen products loaded within
the unit during the tempering or thawing of the beverage products.
After a suitable thawing period, in which the frozen product has
thawed to a suitable partially frozen state, the unit is modified
to limit or substantially prevent airflow through the unit.
[0144] Referring to FIG. 12, unit 200 includes a generally
rectangular housing 202 with an open top end, a bottom wall 203
closing the bottom end of the housing, opposing side walls 204
extending in a longitudinal direction of the housing, and opposing
side walls 206 forming the front and rear ends of the housing. The
housing bottom and side walls define an internal chamber within the
housing that receives and retains the beverage product. In the
embodiment depicted in FIGS. 12-14, housing 202 is suitably
dimensioned to receive six cups of a suitable size (e.g., 12 fluid
ounce cups) within the housing chamber. However, it is noted that
the housing can have any suitable geometric configuration (e.g.,
square, curved, multi-faceted or multi-sided, etc.) and can be
suitably dimensioned to receive any suitable number of cups of any
suitable shapes and sizes (e.g., cups of the shapes and sizes
described above for the previous embodiments) that contain the
frozen beverage product. The housing can further be constructed of
any suitable materials such as the types described above that
preferably provide a suitable level of insulation for the unit by
preventing or minimizing heat transfer between the housing walls
during operation of the unit. Preferably, the housing and other
components of the unit are constructed of a lightweight material
such as cardboard.
[0145] A divider 210 is provided within the housing chamber so as
to section or compartmentalize the housing chamber into
sub-chambers for receiving frozen beverage cups. In the embodiment
of FIGS. 12-14, divider 210 includes a first divider wall that
extends in a longitudinal direction of the housing within the
chamber and two divider walls that extend transverse and generally
perpendicular to the first divider wall so as to section the
housing into six sub-chambers that are about equal dimensions. The
six sub-chambers are configured to receive a single beverage cup.
It is noted, however, that the divider and housing can be designed
so as to form any selected number of sub-chambers within the
housing, where each sub-chamber is configured to receive any
selected number of beverage cups (e.g., one, two or more).
[0146] Housing 202 includes vents or ports 208 extending through
each of the longitudinally extending side walls 204 at a lower
location proximate bottom wall 203 (e.g., at a location from the
bottom wall that is less than about 1/3 the height or distance to
the open top end of the housing). The ports are suitably spaced
such that a single port 208 corresponds and communicates with a
sub-chamber defined by divider 210 within the housing chamber. It
is noted, however, that the housing and divider can be configured
such that any suitable number of ports (e.g., one, two or more) are
provided that correspond and communicate with any suitable number
of sub-chambers (e.g., one, two or more) defined within the housing
chamber.
[0147] Unit 200 further includes a generally rectangular lid 212
with a top wall 212 and a lip 216 formed by side walls extending
from the top wall. The lid is suitably dimensioned to fit over the
open top end of housing 202 so as to provide a closure for the
housing chamber, with the side walls of lip 216 engaging with
corresponding side walls of the housing and extending a suitable
distance along the housing (e.g., at least about 1/3 the height or
distance between the top and bottom ends of the housing). The lid
further includes a plurality of vents or ports 218 extending
through top wall 214. The ports are aligned longitudinally along
the lid top wall such that a single port 218 corresponds and
communicates with a single sub-chamber defined by divider 210
within the housing chamber when the lid is secured to the top end
of the housing. However, it is noted that the housing lid, housing
and divider can be configured such that any suitable number of
ports (e.g., one, two or more) are provided on the lid that
correspond and communicate with any suitable number of sub-chambers
(e.g., one, two or more) defined within the housing chamber.
[0148] The lid and housing are further suitably dimensioned such
that the lid can be secured around the bottom wall and portions of
the side walls of the housing during operation of the unit. In
particular, lid 212 can be inverted in orientation from its
position when secured to the housing top end (e.g., as shown in
FIGS. 12 and 13) and placed under the housing, with top wall 214 of
the lid engaging bottom wall 203 of the housing and lip 216 of the
lid engaging the lower side wall surfaces of the housing (as
depicted in FIG. 14). In this configuration, the lip 216 extends
over and closes ports 208 of housing side walls 204.
[0149] Operation of the unit is now described with reference to
FIGS. 12-14. Initially, it is noted that the frozen beverage
product can be prepared in the same manner as noted for the
embodiment described above and depicted in FIGS. 7-11. Once
prepared, cups of frozen product sealed with lids (with a suitable
air gap or layer being provided between the product and lid at the
top of each cup, as described above in the embodiment of FIGS.
7-11) are loaded into a selected number of units 200. Prior to
loading, the units are prepared by inserting a divider 210 into the
housing 202 of each unit 200, such that individual cups 220 can be
placed within each sub-chamber of each unit housing (as depicted in
FIG. 14). Upon loading of a unit housing 202 with six cups 220, a
lid 212 is secured over the open top end of the housing (as
depicted in FIG. 13). Units 200 that are loaded with frozen
beverage product can be shipped in this configuration, where the
units are preferably maintained at a suitable temperature range
(e.g., in a temperature range from about 10.degree. F.
(-12.2.degree. C.) to about -40.degree. F. (-40.degree. C.)) to
ensure the beverage product remains frozen during transport and
prior to tempering or thawing of the product.
[0150] Prior to placing each unit 200 in service for consumption of
the beverage product, the frozen beverage product must first be
tempered or thawed to achieve a partially frozen beverage product.
This thawing process is achieved by placing each unit 200 in a
refrigeration unit such that each unit is subjected to thermal
treatment at a temperature of about 35.degree. F. (1.67.degree. C.)
to about 41.degree. F. (5.degree. C.). The units are preferably
thermally treated in this manner for a time period ranging from
about 12 hours to about 24 hours or greater. During this thawing
period, air is permitted to flow or circulate within and through
each unit 200 and into the sub-chambers via ports 208 and 218
disposed on the housing 202 and lid 212 of each unit. The
compartmentalization of the unit housings in combination with
individual air flow ports being provided for each sub-chamber
provides a controlled and substantially uniform airflow through
each sub-chamber, which in turn provides a substantially uniform
heat transfer between the air flowing through the unit housings and
individual beverage cups disposed within the housing sub-chambers.
This controlled and uniform thawing of each beverage cup results in
the formation of a partially frozen beverage product having a
desired texture and consistency that is ready for consumption.
[0151] After sufficient thawing of the beverage products within the
units, an operator (e.g., a cafeteria employee) can select a
suitable number of units for removal from the refrigeration unit
and placement in a food service environment (e.g., a lunch line).
Upon removal of a unit 200 from refrigeration, the operator removes
lid 212 from the top end of housing 202 and secures the lid to the
bottom of the housing in the manner described above and depicted in
FIG. 14. The unit is then placed into service, allowing consumers
to freely select one or more beverage cups from the unit. Securing
of the lid at the bottom of the housing effectively seals housing
side wall ports 208, thus minimizing or substantially preventing
airflow through such ports and through the unit. In this
configuration of the unit, cooled or chilled air can be maintained
within each sub-chamber which, in combination with the
compartmentalization of the unit and the insulating properties of
the divider and housing side walls, serves to effectively insulate
the beverage cups and minimize heat exchange between the cups and
the ambient air surrounding the unit. The beverage cups can be
maintained at suitable temperatures for periods up to about 1 hour
or greater in ambient temperature surroundings that range from
about 68.degree. F. (20.degree. C.) to about 85.degree. F.
(29.degree. C.).
[0152] The unit design facilitates selective placement of a
selected number of cups into service at any given time, and
additional units can be transferred from the refrigeration unit to
the foodservice point-of-use location as necessary for a particular
food service operation. In addition, the unit design facilitates
shipment of the frozen product directly within the units and also
easy operation that allows an operator to simply remove the unit
from a freezer and place it into a refrigeration unit (rather than
having to first load the unit with beverage cups) to initiate
thawing of the frozen product. As noted above, the units can be
designed to receive and thermally treat any selected number of cups
of one or more different sizes. The units can further be designed
for a single use (e.g., in an embodiment in which the units are
constructed of cardboard) or, alternatively for multiple uses. When
designed for a single food service operation, the units can be
discarded and/or recycled after usage. Units designed for multiple
operations are cleaned prior to re-use. The units can further
include operating instructions and/or other suitable indicia on any
of the housing side walls or lid.
[0153] The unit of FIGS. 12-14 can further be modified in any
suitable manner to facilitate selective opening and closing of one
or more ports of the unit so as to control airflow through the
unit. For example, the unit can be designed with flaps connected at
the top end of the housing rather than a removable lid. In this
embodiment, the flaps can include one or more vents or ports. The
flaps can further be suitably dimensioned so as to fold over or
overlap each other to close the opening at the housing top end
during transport and thawing of frozen product within the unit. In
addition, the flaps can be configured to fold against the housing
side walls so as close the ports at the bottom of the housing side
walls while opening the housing top end during use of the unit at a
point-of-sale location.
[0154] In another example of a unit including flaps connected at
the top end instead of a removable lid, the unit can be further
modified by providing housing side wall ports at an upper location
on the housing (i.e., near the housing top end) rather than the
housing bottom end. Further, additional ports can be disposed along
the housing bottom wall rather than along the flaps at the housing
top end. In operation of this unit, the frozen product disposed
within the unit is thawed by inverting or turning the unit upside
down such that the housing bottom wall faces upward and the bottom
wall ports are exposed to the ambient air surrounding the unit. The
flaps remain overlapped so as to maintain closure of the housing at
the housing top end (which faces downward toward and rests upon a
support surface after the unit is inverted). Thus, airflow is
facilitated within the housing via the exposed housing bottom wall
ports and the housing side wall ports. After sufficient thawing,
the unit is then inverted to its original position (with the
housing top end facing upward) and the flaps are folded over
against the housing side walls so as to close the side wall ports.
The bottom wall ports of the housing are also effectively closed
due to the bottom wall resting on a support surface. Thus, this
unit design also provides a selective opening and closing feature
for ports and thus facilitates control of airflow and thermal
treatment of beverage cups within the unit.
[0155] The unique designs and configurations of the different
embodiments of portable thermal treatment and storage units and
corresponding methods of the present invention facilitate effective
thermal treatment of food or beverage products that are placed
within such units, where the products are maintained at desired
temperatures and at partially frozen states for extended periods of
time (e.g., at least about 1 hour and/or up to about 6 hours or
more). The thermal treatment and storage units are capable of
providing such effective thermal treatment of the food or beverage
products over the extended time periods without the need for
electrical energy to be provided to the units. In addition, the
portability and stackable features of the units renders the units
easily adaptable for moving to different locations and arrangements
in a point-of-sale foodservice environment, such as a school lunch
cafeteria.
[0156] The unique unit designs provide the further advantages of
rendering the cups of food or beverage product available to the
consumer on a self-service basis, making it unnecessary for a
foodservice worker to be present at the point of service for the
purpose of dispensing and handing out cups of product (e.g., a
slush beverage) from a machine. This feature of the present
invention is particularly advantageous in the context of a high
volume foodservice with a large number of consumers passing through
in a short period of time, such as a school cafeteria. The self
service feature makes it possible for even young school children to
take the product themselves on a "grab 'n go" basis, whereas they
would typically not be permitted to operate a dispensing machine
(e.g., a slush machine) on a self-service basis. Thus, the present
invention provides substantial labor savings in the context of
school cafeteria operations.
[0157] In addition, the portable thermal treatment and storage
units of the present invention facilitate the formation of a slush
beverage product or other partially frozen food or beverage product
from a liquid (e.g., as in the embodiment of FIGS. 1-5) or,
alternatively, from a completely frozen product (e.g., as in the
embodiment of FIGS. 7-11), thus eliminating the need for expensive
slush machines (or other types of processing equipment)
altogether.
[0158] The portable thermal treatment and storage units of the
present invention can be used in a variety of different foodservice
applications including, without limitation, foodservice sites
operated within schools, colleges, office buildings, government
buildings, convention centers, military feeding sites, stadiums,
movie theaters, cruise ships, cocktail bars, casinos, amusement
parks, catered events, buffets, county fairs, and the like.
[0159] While the portable thermal treatment and storage units and
the methods of using such units of the present invention are very
effective in overcoming problems encountered by school cafeterias
and other point-of-sale foodservice operations that require
high-volume availability of food items that are maintained at
certain chilled temperature, the units are also effective for
foodservice operations that do not experience high volume. For
example, the ability to provide slush beverage products or other
partially frozen food or beverage products (e.g., soft serve ice
cream or milk shake products) at multiple locations, which is
facilitated by the units of the present invention, can also be
useful in low volume operations.
[0160] Having described preferred embodiments of portable thermal
treatment and storage units for containing readily accessible food
and beverage items, and corresponding methods for using such units,
it is believed that other modifications, variations and changes
will be suggested to those skilled in the art in view of the
teachings set forth herein. It is therefore to be understood that
all such variations, modifications and changes are believed to fall
within the scope of the present invention as defined by the
appended claims. Although specific terms are employed herein, they
are used in a generic and descriptive sense only and not for
purposes of limitation.
* * * * *