U.S. patent application number 14/193874 was filed with the patent office on 2015-09-03 for printed chocolate structures.
This patent application is currently assigned to Xerox Corporation. The applicant listed for this patent is Xerox Corporation. Invention is credited to Andrew W. Hays, Zahra C. Langford, David A. Mantell.
Application Number | 20150245632 14/193874 |
Document ID | / |
Family ID | 52596320 |
Filed Date | 2015-09-03 |
United States Patent
Application |
20150245632 |
Kind Code |
A1 |
Mantell; David A. ; et
al. |
September 3, 2015 |
PRINTED CHOCOLATE STRUCTURES
Abstract
A method for printing a three-dimensional crystalline structure
such as a chocolate layer wherein, after printing, the material has
a desired crystal structure and a plurality of non-random cavities.
An embodiment can include printing a liquid first layer of material
with a printer onto a second layer of material having a crystal
structure. Subsequently, the printed liquid first layer is
processed to solidify the first layer. During the processing of the
printed liquid first layer, the second layer functions as a crystal
seed layer through physical contact with the printed liquid first
layer and the second layer crystallizes with the crystal structure.
In some embodiments, confections may be formed from high-quality
chocolate, where the confection has a reduced caloric content with
acceptable mouthfeel. In other embodiments, a confection may have a
previously unrealized mouthfeel and taste.
Inventors: |
Mantell; David A.;
(Rochester, NY) ; Hays; Andrew W.; (Fairport,
NY) ; Langford; Zahra C.; (Weed, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Xerox Corporation |
Norwalk |
CT |
US |
|
|
Assignee: |
Xerox Corporation
Norwalk
CT
|
Family ID: |
52596320 |
Appl. No.: |
14/193874 |
Filed: |
February 28, 2014 |
Current U.S.
Class: |
426/104 ;
426/304 |
Current CPC
Class: |
A23G 1/0066 20130101;
A23G 3/0089 20130101; A23G 3/0097 20130101; A23G 1/52 20130101;
B33Y 10/00 20141201; A23G 1/54 20130101; A23G 1/0056 20130101; A23G
1/0006 20130101; A23G 3/545 20130101; A23G 1/50 20130101; B33Y
80/00 20141201; A23G 1/545 20130101; A23P 2020/253 20160801 |
International
Class: |
A23G 3/34 20060101
A23G003/34; A23G 1/00 20060101 A23G001/00; A23G 1/54 20060101
A23G001/54; A23G 3/54 20060101 A23G003/54 |
Claims
1. A method for printing an edible confection having a
three-dimensional crystalline structure, comprising: printing a
liquid first layer of material with a printer onto a second layer
of material having a crystal structure to form a plurality of
walls, wherein each of the plurality of walls physically contacts
the second layer of material and extends from the second layer of
material at an angle; processing the printed liquid first layer to
solidify the plurality of walls; and printing a liquid third layer
of material with the printer onto the second layer of material to
form a ceiling that physically contacts the plurality of walls to
form a plurality of non-random cavities within the confection,
wherein the ceiling comprises a surface that intersects a surface
of the second layer of material at an angle.
2. The method of claim 1, further comprising: cooling the liquid
first layer of material prior to printing the liquid third layer;
using the second layer as a crystal seed layer during the cooling
of the liquid first layer of material, wherein the first layer
crystallizes with the crystal structure during cooling; cooling the
liquid third layer of material; and using the first layer as a
crystal seed layer during the cooling of the third layer of
material, wherein the third layer crystallizes with the crystal
structure during cooling.
3. The method of claim 1, further comprising dispensing a filling
into the plurality of non-random cavities within the
confection.
4. The method of claim 1, wherein the ceiling is a first ceiling
and the method further comprising: dispensing a first filling into
a first cavity; dispensing a second filling that is different from
the first filling into a second cavity; and printing a second
ceiling over the first cavity and the second cavity to seal the
first filling into the first cavity and to seal the second filling
into the second cavity.
5. The method of claim 1 wherein the first layer, the second layer,
and the third layer each comprises chocolate, and the method
further comprises: printing a plurality of chocolate first walls,
wherein each first wall has a first thickness; printing a plurality
of chocolate second walls, wherein each second wall has a second
thickness that is greater than the first thickness; printing a
plurality of chocolate ceilings, wherein at least one of the
plurality of chocolate ceilings contacts the plurality of chocolate
first walls and at least one of the plurality of chocolate ceilings
contacts the plurality of chocolate second walls, wherein the
plurality of first walls, the plurality of second walls, and the
plurality of ceilings form the plurality of non-random cavities
within the confection.
6. The method of claim 5, further comprising forming an outer shell
that seals the plurality of cavities within the confection.
7. The method of claim 6, wherein subsequent to the formation of
the outer shell, the plurality of cavities do not include a solid
or a liquid filling and remain filled only with gas.
8. The method of claim 1, further comprising: filling the plurality
of cavities with a gas comprising at least one of methyl butanoate,
ethyl butanoate, methyl hexanoate, ethyl hexanoate,
.beta.-damascenone, 2-furfurylthiol, 2-isobutyl-3-methoxypyrazine,
guaiacol, 2,3-butanedione, 4-hydroxy-2,5-dimethyl-3(2H)-furanone,
and combinations thereof; and forming an outer shell that seals the
gas within the plurality of cavities within the confection.
9. The method of claim 1, further comprising: printing the liquid
first layer of material using a drop-on-demand printer; and
printing the liquid third layer of material using the
drop-on-demand printer.
10. The method of claim 1, further comprising: printing the liquid
first layer of material using an extrusion printer; and printing
the liquid third layer of material using the extrusion printer.
11. A confection, comprising: a plurality of chocolate walls,
wherein each chocolate wall has a thickness of between 5
micrometers and 10 millimeters; a plurality of non-random cavities
formed at least partly by the plurality of chocolate walls; and an
outer shell that seals the plurality of non-random cavities within
the confection.
12. The confection of claim 11, further comprising a plurality of
chocolate ceilings that intersect the plurality of walls to provide
a plurality of non-random cavities, wherein each chocolate ceiling
has a thickness of between 5 micrometers and 10 millimeters.
13. The confection of claim 12, further comprising a filling that
at least partially fills the plurality of cavities.
14. The confection of claim 12, wherein the plurality of cavities
is a first plurality of cavities and the confection further
comprises: a second plurality of cavities; a first filling that at
least partially fills, and is sealed within, the first plurality of
cavities; and a second filling that at least partially fills, and
is sealed within, the second plurality of cavities, wherein the
first filling is different from the second filling.
15. The confection of claim 12, wherein the plurality of chocolate
walls is a first plurality of chocolate walls having a first
thickness, and the confection further comprises a second plurality
of chocolate walls having a second thickness, wherein the second
thickness is greater than the first thickness.
16. The confection of claim 12, wherein: the plurality of walls is
a first plurality of walls; the plurality of non-random cavities is
a first plurality of non-random cavities having a first width; the
first plurality of walls and the first plurality of non-random
cavities provide a first confection layer; the confection further
comprises: a second plurality of walls; a second plurality of
non-random cavities having a second width that is different from
the first width; the second plurality of walls and the second
plurality of non-random cavities provide a second confection
layer.
17. The confection of claim 16, wherein: the plurality of first
walls has a first thickness; the plurality of second walls has a
second thickness; and the first thickness is different than the
second thickness.
18. The confection of claim 17, further comprising a ceiling that
separates the first confection layer from the second confection
layer.
19. The confection of claim 11, further comprising a floor that
contacts the outer shell and seals the plurality of non-random
cavities within the confection, wherein: the plurality of chocolate
walls extend from the floor to the outer shell; and each cavity
connects to both the floor and the outer shell within the
confection.
20. The confection of claim 11, further comprising: a gas within
the plurality of non-random cavities, wherein the gas comprises at
least one of methyl butanoate, ethyl butanoate, methyl hexanoate,
ethyl hexanoate, .beta.-damascenone, 2-furfurylthiol,
2-isobutyl-3-methoxypyrazine, guaiacol, 2,3-butanedione,
4-hydroxy-2,5-dimethyl-3(2H)-furanone, and combinations thereof.
Description
FIELD OF THE EMBODIMENTS
[0001] The present teachings relate to the field of forming crystal
structures and more particularly to methods for printing a layer
having a desirable crystal structure, for example a chocolate layer
having a desirable degree of crystallization or temper.
BACKGROUND OF THE EMBODIMENTS
[0002] Various compounds can have different crystal structures
depending on factors such as temperature. For example, chocolate,
and more particularly cocoa butter within chocolate, can generally
have one of six crystal structures depending on how it is produced.
The crystal structures range from type I to type VI with each
crystal type having a different melting point. Generally accepted
melting points of cocoa butter crystal types are as follows: type
I: 17.degree. C.; type II: 21.degree. C.; type III: 26.degree. C.;
type IV: 28.degree. C.; type V: 34.degree. C.; type VI: 36.degree.
C. Type VI crystals require an extended duration of time (a matter
of months) to form and are not found in typical chocolate.
[0003] Tempering of chocolate during production is necessary to
produce a product with as many type V crystals as possible, which
is the cocoa butter crystal structure typically used for consumer
chocolate. To temper chocolate to produce type V crystals, the
chocolate can be heated to a temperature which is higher than the
type IV crystal melting temperature, for example 31.degree. C. to
32.degree. C. for a duration of time which is sufficient to melt
the type I to type IV crystals, then cooled. During the cooling,
the type V crystals that remain function as crystallization nuclei,
around which other type V crystals will form.
[0004] In another method of forming type V cocoa butter crystals, a
solid seed chocolate having a preponderance of type V crystal
structures is dispensed into a melted chocolate which is at a
temperature between the type IV and type V crystal melting point.
The type V crystals in the solid chocolate function as
crystallization nuclei for the molten material such that the melted
chocolate crystallizes into a type V cocoa butter crystal
structure.
[0005] Quality chocolate with a type V crystal structure has
desirable characteristics, such as a shiny surface, a firm texture,
a good snap, a melting point which is above typical ambient
temperatures but generally around human body temperature and a
texture and appearance which will not degrade over time.
[0006] Attempts have been made to fashion three dimensional designs
with chocolate using a chocolate dispenser (printer) with a
controlled placement of material. This chocolate printing may
include dispensing an in-temper material. However, due to high
viscosity of in-temper chocolate, the material must be extruded,
which requires a large extrusion nozzle size that has a large
resolution and is thereby unable to form well-defined, small
resolution features. Heating chocolate to a higher temperature to
achieve a lower viscosity can cause the chocolate to lose temper.
Thus current 3D chocolate printers cannot print fine 3D structures
which have a high percentage of cocoa butter type V crystal
structures. Current methods of chocolate printing can result in
printed chocolates that lack the required resistance to elevated
temperatures and other desirable properties of snap, surface
finish, and texture.
[0007] Additionally, current chocolate processing is limited by the
techniques used in the processing. For example, a chocolate
confection might contain a flavored center and an outside coating
of solid chocolate. Current variety in texture consists of using
fillings such as a smooth ganache mixed with nuts or layering
different fillings.
[0008] Further, consumers take cues on how much to eat largely
based on visual appearance of the product before it is consumed
rather than on the actual caloric value of the product itself.
Lowering a product's calorie count by removing fat and/or sugar may
result in a flat and unsatisfying consumer experience. Hollow
chocolate does not produce a desirable consumer experience, as a
bite simply breaks the outer shell and provides no subsequent bite
resistance. Aerated chocolate formed by injecting gas at high
pressures into the molten chocolate has a conventional external
form factor and reduces overall calorie count. However, the
randomized air bubbles provide a less-than-desirable texture as the
product is consumed. Further, the randomized bubbles in the
internal structure of the uneaten portion of the product after an
initial bite are not visually appealing.
[0009] New production techniques and the resulting new confection
designs would be desirable.
SUMMARY OF THE EMBODIMENTS
[0010] The following presents a simplified summary in order to
provide a basic understanding of some aspects of one or more
embodiments of the present teachings. This summary is not an
extensive overview, nor is it intended to identify key or critical
elements of the present teachings nor to delineate the scope of the
disclosure. Rather, its primary purpose is merely to present one or
more concepts in simplified form as a prelude to the detailed
description presented later.
[0011] In an embodiment, a method for printing an edible confection
having a three-dimensional crystalline structure may include
printing a liquid first layer of material with a printer onto a
second layer of material having a crystal structure to form a
plurality of walls, wherein each of the plurality of walls
physically contacts the second layer of material and extends from
the second layer of material at an angle, processing the printed
liquid first layer to solidify the plurality of walls, and printing
a liquid third layer of material with the printer onto the second
layer of material to form a ceiling that physically contacts the
plurality of walls to form a plurality of non-random cavities
within the confection, wherein the ceiling comprises a surface that
intersects a surface of the second layer of material at an
angle.
[0012] In another embodiment, a confection may include a plurality
of chocolate walls, wherein each chocolate wall has a thickness of
between 5 micrometers and 10 millimeters, a plurality of non-random
cavities formed at least partly by the plurality of chocolate
walls, and an outer shell that seals the plurality of non-random
cavities within the confection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate embodiments of
the present teachings and together with the description, serve to
explain the principles of the disclosure. In the figures:
[0014] FIGS. 1-4 are cross sections of a first embodiment of the
present teachings for printing a three-dimensional structure having
a desired crystal structure;
[0015] FIG. 5 is a cross section of a second embodiment of the
present teachings for printing a three-dimensional structure having
a desired crystal structure;
[0016] FIGS. 6-8 are cross sections of a third embodiment of the
present teachings for forming a three-dimensional structure having
a desired crystal structure;
[0017] FIG. 9 is a cross section depicting formation of a
confection according to an embodiment of the present teachings;
and
[0018] FIGS. 10 and 11 are cross sections depicting confections
according to embodiments of the present teachings.
[0019] It should be noted that some details of the FIGS. have been
simplified and are drawn to facilitate understanding of the present
teachings rather than to maintain strict structural accuracy,
detail, and scale.
DESCRIPTION OF THE EMBODIMENTS
[0020] Reference will now be made in detail to exemplary
embodiments of the present teachings, examples of which are
illustrated in the accompanying drawings. Wherever possible, the
same reference numbers will be used throughout the drawings to
refer to the same or like parts.
[0021] As used herein, unless otherwise specified, a "printer"
encompasses any apparatus that performs a deposition of a material
onto a substrate. While the present teachings are described herein
with reference to a printer that prints an edible material,
specifically a chocolate printer, it will be understood that any
edible confectionery material or non-edible material which is
manufactured to include a particular crystal structure and which is
capable of crystallizing through the use of a crystallization
nucleus or crystal seed may advantageously incorporate an
embodiment of the present teachings. Additionally, for purposes of
the present description, the work "ink" is used to refer to any
material that is dispensed by the printer, and can include an
edible material (e.g., chocolate) and/or an inedible material, for
example any element, molecule, compound, or mixture that falls
within the scope of the present teachings. Further, unless
otherwise specified, a "molten" material includes a material that
is in a non-solid form, for example liquid or semi-viscous.
[0022] An embodiment of the present teachings can include printing
a first material which has an undesired crystal to result in a
second material that has a desired crystal shape. The final
structure may be a non-edible material used for commercial or
consumer purposes. The final structure may also be an edible
confection having a desired crystal shape such as a chocolate
structure having a three dimensional (3D) shape. The text below
describes the present teachings with regard to a chocolate layer,
but it will be understood that the present teachings may apply to
any edible or inedible materials. In an embodiment, the completed
3D structure may have a desirable crystal configuration, such as a
type V cocoa butter crystal structure. An untempered molten
chocolate layer can be dispensed or printed upon a tempered
chocolate base layer such as a solid chocolate base layer having a
type V cocoa butter crystal structure. As the molten chocolate is
printed onto the base layer, the solid chocolate base layer
functions as a crystal seed layer or crystallization nucleus
through physical contact with the printed layer. As the molten
chocolate cools, its crystal structure conforms to that of the base
layer to result in a 3D structure having a desired cocoa butter
crystal structure (i.e., a desired temper).
[0023] An embodiment of the present teachings can include a method
and in-process structures which can be formed during an embodiment
of the present teachings, for example as depicted in FIGS. 1-4 and
described in the accompanying text.
[0024] FIG. 1 depicts a substrate 10 and a base layer 12 which
overlies and/or contacts the substrate 10. The substrate 10 can
include a metal layer, a polymer layer, a plastic layer, etc., and
may be electrically and/or thermally conductive. The base layer 12
can be a chocolate base layer having a particular crystal structure
such as a type V cocoa butter crystal structure. In an embodiment,
the base layer 12 can have a thickness of between about 1.0
micrometer (.mu.m) and about 10.0 millimeters (mm), or between
about 1.0 .mu.m and about 3.0 mm, or between about 1.0 .mu.m and
about 1.0 mm. It is contemplated that a layer thinner than 1.0
.mu.m may be sufficient, and the base layer 12 may include a base
layer in dry powder form. The base layer 12 should be sufficiently
thick to cover the substrate 10 at least where a 3D structure will
be printed. For example, the base layer 12 can cover the entire
upper surface of the substrate 10, or a perimeter of the substrate
10 can be exposed around a centrally located base layer 12. A base
layer 12 which is insufficiently thick can include undesirable gaps
or may fail to retain its crystalline form when hot ink is printed
thereon. In certain embodiments of the present teachings, an
excessively thick base layer 12 may not allow for processing as
described below.
[0025] In an embodiment, the base layer 12 can be applied to the
substrate 10 as a molten layer having a type V crystal structure
which coats at least a portion of an upper surface of the substrate
10. After application, the molten base layer 12 can be cooled such
that it solidifies with a type V crystal structure. In another
embodiment, the molten base layer 12 applied to the substrate 10
can have a first crystal structure, for example that is not type V
(which may be no crystal structure, a type I-type IV crystal
structure, a type VI crystal structure, or mixtures thereof), and
then tempered after placement on the substrate 10 to have a desired
second crystal structure, such as a type V crystal structure.
Tempering of the first crystal structure to the second crystal
structure can be performed by heating the material on the substrate
10, then cooling the material.
[0026] In an embodiment, a thermally conductive substrate 10 can be
actively heated with an optional powered internal heat source 14
such as a coil that is electrically connected (i.e., electrically
coupled) to power 16 and ground 18, which is heated to a
temperature or a series of temperatures in order to temper the
liquid, solid, powdered, or granulated base layer 12, or for other
uses as described below. In another embodiment, structure 14 can
represent an optional powered internal cooling source 14 such as a
cooling coil which is cooled to more quickly solidify a melted base
layer 12 to decrease manufacturing time. In another embodiment,
element 14 can represent both an optional heat source and an
optional cooling source, so that the substrate 10 can be heated and
cooled as desired.
[0027] After forming the base layer 12 having a desired crystal
structure, a printer or printhead 20A is used to deposit a first 3D
structure layer 22 onto the base layer 12 as depicted in FIG. 2. It
will be apparent to one of ordinary skill in the art that the
structures such as printer 20A, substrate 10, etc., depicted in the
FIGS. represent generalized schematic illustrations and that other
structures or elements can be added or existing structures or
elements can be removed or modified. In an embodiment, the printer
can include a reservoir 24A which contains a supply of material 26
and, in this embodiment, a plurality of nozzles 28A through which
the material 26 is printed or extruded under pressure. For printing
of chocolate material 26, the chocolate can be heated to a
temperature that is sufficient to soften or melt all of the cocoa
butter crystals, for example to a temperature of above 40.degree.
C., for example between about 40.degree. C. to about 60.degree. C.
Additionally, chocolate at this temperature has a viscosity that is
sufficiently low so that the chocolate 26 is ejected or flows
easily through the printer 20A and out of the nozzle 28A. However,
heating chocolate to this temperature for a low viscosity material
causes the chocolate to lose its temper, as the temperatures
required to generate the desired in-temper crystals forms a
material that is very thick and does not flow with sufficient ease
for printing.
[0028] Printer 20A may be, for example, a drop-on-demand (DOD) ink
jet printer. Ink, for example chocolate, can be ejected as a
plurality of droplets 29 through the nozzles using a transducer
such as a piezoelectric element which deflects a diaphragm as known
in the art. The printer 20A may be a printer other than a DOD ink
jet printer, such as an extrusion printer, a solid ink printer, or
a printer which uses other ink printing technology. In the case of
an extrusion printer, for example, droplets 29 depict extruded
material 26. In the case of a DOD printer, for example, the
droplets 29 can be simultaneously ejected from the plurality of
nozzles 28A as individual droplets but can be printed with
sufficient density so as to form a uniform first layer 22 having a
desired thickness.
[0029] As the first layer 22 is deposited onto the in-temper
chocolate base layer 12, the base layer 12 seeds crystallization in
the first layer 22. As the first layer cools, its crystals take on
the crystal configuration of the base layer 12 to form an in-temper
3D first layer 22. The substrate 10 may be cooled using a powered
internal cooling source 14 to decrease cooling time. As will be
understood by one of ordinary skill, the first layer 22, as well as
subsequent layers as described below, must be cooled slowly enough
to allow sufficient crystal growth or formation. Cooling the
material too quickly may not allow sufficient time for the
nucleating crystals to grow throughout the thickness of the new
drop or line of material using the crystal structure of the base
layer 12 as a crystal seed layer. In another embodiment, the
substrate 10 can be slightly heated to increase cooling time of the
chocolate first layer 22 to maximize crystal formation.
Additionally, ambient air around the cooling surfaces can be
actively or passively dehumidified to reduce or prevent water
contamination of the surface. In an embodiment, the ambient air
around the cooling surfaces is dehumidified to a humidity of 50% or
less.
[0030] Subsequently, a 3D second layer 30 can be printed using the
printer 20B as depicted in FIG. 3. FIG. 3 depicts a different
printer 20B for illustration purposes. In contrast to printer 20A
having a plurality of nozzles 28A, printer 20B includes a single
nozzle 28B which prints all material. Printer 20B can be a single
nozzle DOD printer, an extrusion printer, etc. Generally, the same
printer may be used to print each of the printed layers.
[0031] Because the crystal structure of the 3D first layer 22 takes
on the crystal structure of the base layer 12, the second layer 30
takes on the crystal structure of the 3D first layer 22 through
physical contact, such that the first layer 22 function as a
crystallization nucleus for the second layer 30.
[0032] Similarly, any number of additional layers 32 can be printed
to build or manufacture a desired 3D shape as depicted in FIG. 3. A
delay can be implemented after printing each layer so that a
printed layer sufficiently cools and crystallizes before applying a
subsequent layer. In an embodiment, the base layer 12 can have a
first color, the first layer 22 can have a second color that can be
the same or different from the first color, and any of the
additional layers 32 can have a third color that is the same or
different than the first color and/or the second color.
[0033] After the 3D structure 40 has been completed, it may be
removed from the base layer 12 as depicted in FIG. 4. In an
embodiment, the 3D structure may be removed from the base layer 12
using a blade, which may or may not be heated, to separate the 3D
layer 40 from the base layer 12. In another embodiment, the
optional heat source 14 within the substrate 10 can be heated
sufficiently to soften the base layer 12, and the 3D structure 40
can be lifted from the base layer 12 using mechanical techniques or
by a human operator. In yet another embodiment, a very thin base
layer 12 or a base layer 12 in powder or granulated form is used
such that regions of the base layer 12 which do not have an
overlying layer of printed material 22, 30, 32 are left behind on
the substrate 10 when the 3D structure is removed.
[0034] It is contemplated that, generally, the base layer 12 may
remain as a part of the completed 3D structure. If the base layer
12 is to remain as part of the 3D structure, the base layer 12 can
be formed on a release layer 50 to facilitate removal of the
structure including layers 12, 22, 30, and 32 from the substrate
10. In an embodiment, for example when printing a chocolate layer
as the ink, the release layer 50 can be a parchment paper or
another release layer. As depicted in FIG. 5, the release layer 50
is interposed between the substrate 10 and the base layer 12 to
facilitate removal of the 3D structure 40, including the base layer
12, from the substrate 10.
[0035] In another embodiment in which the base layer 12 is not part
of the 3D structure, the release layer 50 as depicted in FIG. 5 can
be placed onto the substrate 10 prior to formation of the base
layer 12, or the base layer 12 can be formed on the parchment paper
50, and the assembly including the parchment paper 50 and the base
layer 12 can be placed onto the substrate 10. Subsequently, the 3D
structure 40 is formed according to the present teachings. Next,
the parchment paper 50 with the overlying layers 12, 40 are removed
from the substrate 10.
[0036] In another embodiment, after forming the 3D structure as
depicted in FIG. 5, the parchment paper 50, base layer 12, and 3D
structure 40 can be lifted off the substrate 10. Due to the low
adhesion of the parchment paper 50, the paper 50 can be peeled off
the base layer 12. Next, the base layer 12 can be abraded away
using one of the techniques described above, or melted away, to
leave the 3D structure 40.
[0037] Another embodiment of the present teachings is depicted in
the cross sections of FIGS. 6-8. As depicted in FIG. 6, a base
layer 60 is formed on a substrate 10 to a sufficient thickness to
function as a seed layer for one or more subsequent layers
deposited using a printer 20A, such as a DOD printer. In this
embodiment, the base layer 60 is a seed layer in crystal powder or
granule form. After layering the substrate 10 with the powder base
layer 60, the printer 20A prints a desired first layer 62 which
includes portions 62A and 62B by ejecting a plurality of ink
droplets 29 from the nozzles 28A in accordance with other
embodiments of the present teachings. Because the printer 20A is a
drop-on-demand printer, various different shapes as desired can be
printed. In this embodiment, the base layer 60 has a desired
crystal structure while the droplets 29 are heated for printing,
and have a crystal structure which is different from the base layer
60. Through contact with the base layer 60, which functions as a
crystal seed layer, the printed first layer 62 takes on the crystal
form of the base layer 60.
[0038] Next, a second layer of crystal powder 70 is applied over
the substrate 10 as depicted in FIG. 7. The second layer of crystal
powder 70 can include the same material as base layer 60.
Subsequently, a second printed layer 72 including portions 72A-C is
printed over the crystal powder 70. Through contact with the
crystal powder 70, portions 72A and 72C form with the crystal
structure of the crystal powder 70 by using the crystal powder 70
as a crystallization nucleus. Portion 72B contacts both the crystal
powder 70 and the first layer 62B, and thus forms with the crystal
structure of the powder 70 and the first layer 62B. Additional
powder layers can be deposited and additional layers can be printed
as desired to form a 3D structure.
[0039] Next, the powder layers 60, 70 are removed. The powder
layers 60, 70 can be removed by any sufficient process, for example
by blowing the powder layers away using an air stream, by vacuuming
the layers away, by rinsing, or removed using some other removal
process. After the crystal powder layers 60, 70 are removed, the
desired 3D structure as depicted in FIG. 8 remains.
[0040] By printing chocolates with a drop-on-demand printhead, a
much greater variety of structures is possible. One textural option
includes the formation of cavities (i.e., chambers) 90 within the
chocolate structure 92 as depicted in FIG. 9 to provide previously
unrealized "mouthfeel" and taste. These cavities 90 may be
controlled and formed by printing structures such as columns (i.e.,
walls, pillars) 94, a base (i.e., floor) 12, ceilings 96, ceilings,
etc., where the floor(s) and ceiling(s) intersect the walls. The
floors, walls, and ceilings may be formed on the order of
sub-millimeter to several millimeters thick. In an embodiment, each
cavity may have a cross sectional dimension (length and/or width)
of between about 5 .mu.m and about 10 mm, or between about 10 .mu.m
and about 1.0 mm, or between about 20 .mu.m and about 100 .mu.m.
These cavities 90, which may have a cubic, rectangular cuboid,
tetrahedral, octahedron, or other three-dimensional polyhedron
shape, may be optionally filled with any desired chocolate or
non-chocolate filling material 98A-98C, and different cavities 90
may be filled with the same or different materials in the same
confection piece, and unfilled 100 cavities can be combined with
filled cavities to provide a unique mouthfeel. A plurality of
fillings 98A-98C can be distributed by location in the confection
if the filling consistency lends itself to printing, or the filling
98 can be dispensed using a different dispensing method. If a
printer or printhead 20A is used to dispense the filling 98, the
drop-on-demand printhead that prints a chocolate mesh (i.e., web,
matrix, or lattice) 94-98 may be used, or a different
drop-on-demand printhead having a different form factor such as
larger nozzle sizes may be used. In addition, structures that are
neither filled nor totally closed can be utilized, for example to
alter and customize the experience of eating. Variety in the
experience typically increases a consumer's pleasure and can extend
the time of the consumer's interest from the first bite through the
entire process of eating.
[0041] FIG. 9 depicts a confection 102 during printing. At a first
stage 102A, a DOD printer 20A prints walls 94 onto a floor 96 that
has a desired temper. Using the floor 96 as a crystallization
nucleus, the walls 94, printed at a temperature sufficient to melt
the chocolate to a flowable and printable state as discussed above,
which crystallizes during cooling through contact with the floor
96. In a second stage 102B, an optional filling 98A may be
dispensed into the cavities 90, either by printing using DOD
printhead 20A, a different DOD printhead, or using another
technique. In a different embodiment, the cavities remain unfilled.
After dispensing optional filling 98A, a ceiling 96 may be printed
using the DOD printhead 20A. Subsequently, additional layers may be
formed by continuing the process to form a completed confection
102C. A confection may be formed layer-by-layer to provide any
number of desired layers.
[0042] Various arrangements of walls and cavities are contemplated,
some of which are depicted in the cross section of FIG. 10. For
example, for a single confection 104, the wall may be solid across
the entire level (i.e., no cavity), for example as depicted in
Level 1 (L1) of FIG. 10, or a level may be entirely hollow (i.e.,
no walls other than the exterior) as depicted in level 4 (L4).
Further, any walls (and thus the cavities) may be distributed
symmetrically across the level as depicted in level 2 (L2), or the
walls may be asymmetrically distributed across the level as
depicted in level 3 (L3). As further depicted, the walls may have
different thicknesses as well as different configurations. For
example, the walls in L2 are three times the thickness of the walls
in L3. If the walls are formed across an entire width of the
confection as depicted in L1, then more bite resistance will be
provided in that direction. If the walls are only partially formed
across the width of the confection as depicted in L2 and L3, or the
level is hollow as depicted in L4, then the structure will more
readily collapse and the confection will provide less bite
resistance. By using the selective formation of walls and
floors/ceilings, the collapse of the structure on initial bites may
be engineered to provide a varying consumer experience. Various
parts of the confection can be engineered with directional
structures, such as oblique walls of equal or varying thicknesses,
walls that extend at an angle from a floor or ceiling, and various
angles (not individually depicted for simplicity) that vary the
experience within even a single bite.
[0043] As discussed above, consumers take cues on how much to eat
largely based on visual appearance of the product before it is
consumed rather than on the actual caloric value of the product
itself. Lowering a product's calorie count by removing fat and/or
sugar may result in a flat and unsatisfying consumer experience.
Hollow chocolate does not produce a desirable consumer experience,
as a bite simply breaks the outer shell and provides no subsequent
bite resistance. Aerated chocolate formed by injecting gas at high
pressures into the molten chocolate has a conventional external
form factor and reduces overall calorie count. However, the
randomized air bubbles provide a less-than-desirable texture as the
product is consumed. Further, the randomized bubbles in the
internal structure of the uneaten portion of the product after an
initial bite are not visually appealing.
[0044] In an embodiment of the present teachings, a high quality
confection may be engineered and manufactured with a drop-on-demand
printhead to have a lower calorie count than other confections
while maintaining an ordered and/or non-random internal structure,
as well as an external form factor and mouthfeel that are similar
to conventional, non-aerated chocolate. The internal structure is
non-random, at least because the confection floors, walls, and
ceilings are designed prior to printing and programmed into the
printer, which prints the designed confection internal structure
during printing. A mesh of crystalline chocolate with relatively
thicker vertical walls parallel to the bite direction and
relatively thinner horizontal supports perpendicular to the bite
direction, for example similar to level L2 in the confection 104 of
FIG. 10 (with the bite direction being vertical with respect to
FIG. 10), may be printed to provide a confection that provides a
suitable mouthfeel while reducing the number of calories.
Variations of the size and interconnected chocolate can be
engineered to provide different and desirable mouthfeels. Thin
structures, such as the walls in L3, will collapse more easily,
while thick structures, such as L1 and the walls of L2, can be
designed to provide significantly more bite resistance that mimics
a conventional chocolate while providing fewer calories through the
incorporation of ordered space within the chocolate. Thus different
chocolates can be designed to behave and feel differently in the
mouth.
[0045] Similarly, the length of individual segments of chocolate
within the internal structure will affect mouthfeel. Hollow space
above or below a segment, such as L4 in FIG. 10, will collapse from
a bite before the segment can provide significant resistance. Long
segments such as L1 can provide resistance sooner in a bite, while
shorter ones such as L2 provide resistance only after all the
hollow spaces have collapsed or been filled with chocolate from a
different level as the bit reduces the size.
[0046] Another potential benefit of ordered, non-random structures
within the chocolate may be to provide increased surface area. This
provides more opportunities for the release of volatile compounds
such as aroma extracts of cocoa beans, for example, 2- and
3-methylbutanoic acid, acetic acid, 3-methylbutanal,
4-hydroxy-2,5-dimethyl-3(2H)-furanone, 2- and 3-methylbutanoic
acid, 3-methylbutanal and phenylacetaldehyde,
4-hydroxy-2,5-dimethyl-3(2H)-furanone, 3-methylbutanoic acid, ethyl
2-methylbutanoate, and 2-phenylethanol, and combinations of two or
more of these. Additionally, ordered, non-random structures within
the chocolate may allow saliva to better mix with the confection.
Either of these uses may potentially enhance the intensity of the
flavor. Further, a plurality of very fine chocolate whiskers on the
order of 100 microns thick dispensed into the internal confection
mesh during manufacture of the chocolate may be included to extend
into the gaseous volatile compounds. The plurality of whiskers
provide a very high surface area with a small amount of material,
potentially greatly enhancing the release of volatile compounds
once the outer surface of the chocolate is broken. Chocolate
whiskers may be printed to have a diameter of between about 10
.mu.m and 30 .mu.m, for example about 20 .mu.m, and a height of
between about 5 mm and about 20 mm, for example about 12 mm.
[0047] Variable forms mentioned in previous examples, including
walls of different target thickness and target lengths, can be
provided within a single chocolate. This may allow a single
confection to provide different mouthfeels depending on the
orientation of the confection during a bite by the consumer. If
long wall segments are only provided in one direction but across
the whole confection, then biting parallel to that direction
provides significant resistance, while biting perpendicular
provides much less resistance. So a consumer can be encouraged to
experience the confections in different ways depending on how the
confection is oriented relative to the teeth. Another variation may
include manufacturing walls of different thicknesses or lengths in
different parts of the confection. Thin walls toward the outer
portion of the confection will collapse easily on an initial
portion of a bite, while thicker walls toward the middle of the
confection will provide significant resistance as the bite is
completed. Thus the mouthfeel provides low resistance at first but
will increase significantly later in the bite.
[0048] Chocolate comes in many different states depending on how it
is processed and its origin (variety of tree, growing location,
fermentation, drying, roasting, alkalization, additional
ingredients and conching. In an embodiment, these different
varieties can be incorporated as separate homogeneous structures
(as opposed to simply mixing different varieties in a heterogeneous
mixture) within a single confection such as a candy bar to release
unique volatile profiles from different parts of the candy bar. For
example, these homogeneous volatile profiles can be stored in
different cavities within the chocolate bar (for example, as
depicted in FIG. 9) by making the walls surrounding those cavities
out of a particular variety of chocolate. In an embodiment, an
inexpensive chocolate type, for example a chocolate that has been
conched for a minimal amount of time, may form some walls of the
confection, for example L2 in FIG. 10, while an expensive
chocolate, for example a chocolate that has been conched for up to
72 hours, may be used for other layers such as L3, such that the
expensive chocolate aromatics dominate. In an embodiment, an
inexpensive chocolate substructure that forms the interior mesh may
be coated with an expensive chocolate shell.
[0049] As discussed above, any open mesh structures described above
can be filled, for example by injecting a fluid or viscous material
98 into the walled receptacles or cavities. A filling will change
the mouthfeel of the chocolate. Partially filled cavities will
behave differently from fully filled ones, and cavities filled with
a viscous but still liquid fruit flavor will be experienced
differently from ones filled with solid but soft materials such as
a ganache. Other confections may include different fillings that
are individually (separately) encapsulated within a mesh and
enclosed within the interior of the confection. The fillings may be
added during confection manufacture by printing a floor and
vertical walls to form a plurality of cavities, dispensing a
different filling, or the same filling, within each cavity,
printing a ceiling over the one or more fillings to fully
encapsulate the filling, and then optionally forming additional
cavities and fillings over the initial structures to construct a
confection layer-by-layer. The regions where the chocolate is
printed may be contiguous to previously hardened/crystalized
chocolate to result in the proper crystalline form using the
previous chocolate material as a crystallization nucleus.
[0050] In an embodiment, horizontal ceilings over hollow cavities
may be formed by slightly overlapping a chocolate drop such that it
physically contacts a previously formed and cooled drop. This may
result in a confection such as 140 depicted in FIG. 11 having an
angled ceiling 142 connected to vertical walls 144, wherein a
surface of the angled ceiling 142, for example a curved or
generally planar surface, intersects a surface of the vertical wall
144, for example a curved or generally planar surface, at an angle
of greater or less than 90.degree.. In another embodiment, such as
confection 112 in FIG. 11, the formation of a horizontal ceiling
124 having a planar surface that contact a planar surface of a
vertical wall 122 using this technique is also contemplated. In
another embodiment, a plurality of vertical walls 94 may be formed
as depicted in 102A of FIG. 9, and then the structure 102A may be
rotated, for example by 90.degree. or another angle, such that the
ceilings 96 are formed in a more vertical direction and the walls
intersect the ceiling at 90.degree., or between about 85.degree.
and about 95.degree.. After formation of at least part or all of
the ceiling 96, the structure may be rotated back into the
orientation of 102A to form the walls 94 of the next level on the
ceiling 96.
[0051] Final closing of the internal mesh structure may be
performed in several ways. For example, if the fillings are
dispensed by printing them into the cavities of the mesh using a
DOD printhead, the openings may be closed by printing chocolate
around the opening using a DOD printhead as depicted in FIG. 9,
allowing each chocolate drop to be physically connected to
previously printed chocolate so that proper crystallization occurs.
In an alternate embodiment, if extra chocolate is printed around an
opening, for example to inject a filling, then the chocolate may be
re-melted to a temperature below the tempering point to allow the
chocolate to spread and close the opening. In another embodiment, a
properly tempered chocolate piece may be placed to cover the
opening before a printed melted region around the opening has
solidified. In another embodiment, the entire structure may be
coated by properly tempered chocolate by conventional methods such
as dipping or pouring.
[0052] It is contemplated that substances including volatile gas
compounds such as fruity, savory, spicy, coffee, etc., esters, for
example methyl butanoate, ethyl butanoate, methyl hexanoate, and
ethyl hexanoate for coffee flavors, .beta.-damascenone for an aroma
like cooked apples, 2-furfurylthiol for a sulfury or roasty flavor,
2-isobutyl-3-methoxypyrazine for an earthy flavor, guaiacol for a
spicy flavor, 2,3-butanedione for a buttery flavor, and
4-hydroxy-2,5-dimethyl-3(2H)-furanone for a caramel flavor, among
others, may be incorporated into the chocolate cavities of a mesh
to maximize a contribution of odor to the taste sensation that is
experienced while contributing little to the caloric content of the
confection. These volatile compounds may be incorporated into the
confection by manufacturing the confection in a closed (i.e.,
sealed) cavity filled with the volatile gas. The inclusion of
volatile compounds can be increased by chilling the cavity during
manufacture to form a concentrated gas incorporated into the
internal mesh of the confection. After dispensing the filling into
the cavity, either by DOD printing or some other dispensing
technique, the cavity may be sealed by printing a ceiling to
prevent outgassing of the volatile compound. In another embodiment,
the volatile compounds may be trapped within other edible liquid or
viscous carrier materials and dispensed into one or more cavities
within the confection as a filling.
[0053] When including layers of filling, the top of the filling
itself is not a nucleation site. These regions may be bridged by
properly tempered chocolate by printing out from a wall of
previously printed, properly tempered chocolate that will nucleate
the subsequently printed ceiling that seals the filling within the
chocolate mesh. Untempered chocolate on the outside of a confection
is undesirable, as chocolate that is not properly tempered lacks
snap, shine, and tends to melt at lower temperatures, for example
when handled. However, these qualities are not necessarily
detriments for structure within the interior of a confection.
Printing non-tempered chocolate structures over fillings without
connecting to nucleated regions while printing a properly tempered
chocolate on the outside may result in a desirable confection that
has a soft, quickly melting interior.
[0054] In an embodiment, different fillings may be provided on
different layers of a confection. For example, fillings may be
varied from the inside to the outside of a confection, or from one
side to another. This would allow, for example, a bar of chocolate
to have encapsulated flavorings that vary from a first end of the
confection (such as a candy bar) to a second end opposite the first
end, or a confection that has segments, for example segments that
may be physically separated by the consumer prior to eating, that
vary by flavor.
[0055] In another embodiment, the 3D printing embodiments of
various embodiments may be used to form external structures with
different textures. In other words, some of the
pillars/walls/cavities may be on the external surface of the
confection. These would allow a consumer to place the confection in
their mouth and experience the textural variety without chewing.
Besides being decorative, these structures, if sufficiently tall,
might significantly change the eating experience. For example, for
only a moment after putting the confection into the mouth, only the
tops of the structures would melt, yet saliva would interact with a
greater surface area to produce a more intense flavor. Overall, the
melting of the pillars, texturally, would be noticeably different
to the tongue, which would initially contact the pillars in fewer
places. Because of the open structure, the pillars may be brought
up to mouth temperature more quickly and thus melts more quickly
than will a solid block of chocolate of the same volume.
[0056] Various confection configurations printed using a DOD
printer or an extrusion printer according to a method discussed
above are depicted in the cross sections of structures 110, 112,
114, and 140 in FIG. 11. For example, confection 110 includes an
outer shell 116, a plurality of vertical walls (parallel with
respect to the bite direction) 118, and a plurality of hollow
cavities 120, although it is contemplated that each cavity 120 may
include the same or different fillings. In this embodiment, the
confection does not include horizontal ceilings internal to the
confection. The vertical walls may be formed from different
chocolate types, or the same chocolate type, and the outer shell
116 may be formed from the same chocolate type, or a different
chocolate type, from the walls 118. The vertical walls of
confection 110 extend from the floor to the outer shell 116, and
each cavity 120 exposes both the floor and the outer shell 116
within the confection (i.e., the space within the cavity contacts
the floor and the outer shell, or connects the floor to the outer
shell with the space within the cavity). Confection 112 includes an
outer shell 116, a plurality of vertical walls 122, a plurality of
horizontal walls 124, and a plurality of hollow cavities 126 that
form a mesh, although the cavities may be filled with the same or
different fillings. The cavities 126 are irregular in shape between
adjacent levels, and the outer shell seals the plurality of
cavities within the confection. Confection 114 includes a
particular arrangement of fillings, including a first filling 128,
a second filling 130 that is different from the first filling 128,
and a third filling 132 different from the other two fillings 128,
130, and a fourth filling 134 different from the other three
fillings 128, 130, 132. The first filling 128 is only located at
the top, while the second filling 130, located at the lower
exterior portion of the confection 114, surrounds the third 132 and
fourth 134 fillings that are located in the center of the
confection 114. Confection 140 depicts angled ceilings 142
connected to vertical walls 144 and a plurality of hollow cavities,
which may also be filled.
[0057] Thus the present teachings can result in a printed 3D
structure, for example a chocolate structure that has a desired
crystalline structure. In the case of chocolate, the 3D structure
can have a desirable temper, for example a type V cocoa butter
crystal structure. An in-temper base layer can be used as a
crystallization nucleus or crystal seed for a printed chocolate
layer. The base layer can be formed mechanically without the use of
3D printing. The base layer should be sufficiently thick so as to
prevent complete melting to the point of losing its crystalline
structure when a drop of chocolate or a chocolate strip at elevated
temperatures is printed on top. This base layer then functions as a
crystal seed to nucleate crystallization of the chocolate printed
on top in the desired form. Subsequent drops or strips of chocolate
will then be nucleated by the previous drops in the proper crystal
form.
[0058] The chocolate in-temper base layer serves a number of
purposes. First, by acting as a nucleation site, it accelerates the
rate of solidification of the chocolate printed thereon. Second,
the chocolates produced using the printer can be in temper. Third,
because the printed chocolates are in temper, they have the
desirable characteristics associated with in-temper chocolates,
such as being more stable with a higher melting point than
untempered chocolates, a desirable snap, and a shiny surface.
[0059] For use with materials other than chocolate, it is
contemplated that a liquid material printed with a non-desirable
crystal structure can be processed, for example by heating, to
remove (evaporate) one or more solvents or other thinning component
and to solidify the liquid material to form a solid layer. As the
solvent is removed the liquid printed material is seeded to a
desired crystal structure by the base layer as the liquid printed
material solidifies. For application to food, a typical solvent
would be water and typical seed materials would be one or more
crystals of sugar or one or more crystals of salt.
[0060] Notwithstanding that the numerical ranges and parameters
setting forth the broad scope of the present teachings are
approximations, the numerical values set forth in the specific
examples are reported as precisely as possible. Any numerical
value, however, inherently contains certain errors necessarily
resulting from the standard deviation found in their respective
testing measurements. Moreover, all ranges disclosed herein are to
be understood to encompass any and all sub-ranges subsumed therein.
For example, a range of "less than 10" can include any and all
sub-ranges between (and including) the minimum value of zero and
the maximum value of 10, that is, any and all sub-ranges having a
minimum value of equal to or greater than zero and a maximum value
of equal to or less than 10, e.g., 1 to 5. In certain cases, the
numerical values as stated for the parameter can take on negative
values. In this case, the example value of range stated as "less
than 10" can assume negative values, e.g. -1, -2, -3, -10, -20,
-30, etc.
[0061] While the present teachings have been illustrated with
respect to one or more implementations, alterations and/or
modifications can be made to the illustrated examples without
departing from the spirit and scope of the appended claims. For
example, it will be appreciated that while the process is described
as a series of acts or events, the present teachings are not
limited by the ordering of such acts or events. Some acts may occur
in different orders and/or concurrently with other acts or events
apart from those described herein. Also, not all process stages may
be required to implement a methodology in accordance with one or
more aspects or embodiments of the present teachings. It will be
appreciated that structural components and/or processing stages can
be added or existing structural components and/or processing stages
can be removed or modified. Further, one or more of the acts
depicted herein may be carried out in one or more separate acts
and/or phases. Furthermore, to the extent that the terms
"including," "includes," "having," "has," "with," or variants
thereof are used in either the detailed description and the claims,
such terms are intended to be inclusive in a manner similar to the
term "comprising." The term "at least one of" is used to mean one
or more of the listed items can be selected. Further, in the
discussion and claims herein, the term "on" used with respect to
two materials, one "on" the other, means at least some contact
between the materials, while "over" means the materials are in
proximity, but possibly with one or more additional intervening
materials such that contact is possible but not required. Neither
"on" nor "over" implies any directionality as used herein. The term
"conformal" describes a coating material in which angles of the
underlying material are preserved by the conformal material. The
term "about" indicates that the value listed may be somewhat
altered, as long as the alteration does not result in
nonconformance of the process or structure to the illustrated
embodiment. Finally, "exemplary" indicates the description is used
as an example, rather than implying that it is an ideal. Other
embodiments of the present teachings will be apparent to those
skilled in the art from consideration of the specification and
practice of the disclosure herein. It is intended that the
specification and examples be considered as exemplary only, with a
true scope and spirit of the present teachings being indicated by
the following claims.
[0062] Terms of relative position as used in this application are
defined based on a plane parallel to the conventional plane or
working surface of a workpiece, regardless of the orientation of
the workpiece. The term "horizontal" or "lateral" as used in this
application is defined as a plane parallel to the conventional
plane or working surface of a workpiece, regardless of the
orientation of the workpiece. The term "vertical" refers to a
direction perpendicular to the horizontal. Terms such as "on,"
"side" (as in "sidewall"), "higher," "lower," "over," "top," and
"under" are defined with respect to the conventional plane or
working surface being on the top surface of the workpiece,
regardless of the orientation of the workpiece.
* * * * *