U.S. patent application number 15/147013 was filed with the patent office on 2016-09-01 for self contained popcorn popper.
The applicant listed for this patent is Gold Medal Products Co.. Invention is credited to Timothy Allan Rhome.
Application Number | 20160249658 15/147013 |
Document ID | / |
Family ID | 34919372 |
Filed Date | 2016-09-01 |
United States Patent
Application |
20160249658 |
Kind Code |
A1 |
Rhome; Timothy Allan |
September 1, 2016 |
Self Contained Popcorn Popper
Abstract
An improved popcorn popper (10) has effluent filtration
structure to treat the oil laden vapor and steam effluent from
popping popcorn within the popper and with discharge of effluent
having less than 5 milligrams of particulates per cubic meter of
effluent discharged directly into the area in which the popper (10)
is located. There is no need for external hoods or for external
ducting of effluent to outside the area and facility in which the
popcorn is popped. The filtering is carried out within the popper
(10). A fire suppression system is provided to handle fires even
within the kettle (14). Methods are disclosed.
Inventors: |
Rhome; Timothy Allan;
(Cincinnati, OH) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Gold Medal Products Co. |
Cincinnati |
OH |
US |
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Family ID: |
34919372 |
Appl. No.: |
15/147013 |
Filed: |
May 5, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13560433 |
Jul 27, 2012 |
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15147013 |
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13004168 |
Jan 11, 2011 |
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13560433 |
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10560540 |
Dec 13, 2005 |
7874244 |
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PCT/US05/06478 |
Feb 28, 2005 |
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13004168 |
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60548538 |
Feb 27, 2004 |
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Current U.S.
Class: |
99/323.5 |
Current CPC
Class: |
A23L 7/183 20160801;
A23V 2002/00 20130101; F24C 15/20 20130101; A23L 7/187
20160801 |
International
Class: |
A23L 1/18 20060101
A23L001/18 |
Claims
1. A self-contained popcorn popper for use in an area, comprising:
a cabinet including a popcorn receiving chamber having a top wall;
a popcorn popping kettle assembly including a kettle and a kettle
top located entirely within the popcorn receiving chamber and
spaced from the top wall thereof; a popped popcorn bin in the
popcorn receiving chamber for receiving popped popcorn from the
kettle; a filter passage having an inlet located below the top wall
of the popcorn receiving chamber so as to be located inside the
popcorn receiving chamber of the cabinet, said inlet being in fluid
communication with said kettle assembly; a plurality of filtration
stations within the filter passage for removing particulates from a
vapor effluent issuing from the popping of popcorn in said kettle;
and a blower for sucking vapor effluent into said inlet and through
said passage so as to discharge filtered effluent into said area
located outside of said cabinet.
2. A popper as in claim 1 wherein said inlet, passage and blower
are contained in said cabinet.
3. A popper as in claim 1 wherein the blower is located entirely
outside the popcorn receiving chamber.
4. A popper as in claim 2 wherein said blower includes an effluent
outlet discharging into said cabinet and said effluent being vented
outwardly of said cabinet into said area.
5. A popper as in claim 4 wherein said inlet is located in an upper
portion of said cabinet and said blower is located in a lower
portion of said cabinet.
6. A popper as in claim 2 wherein said cabinet has two opposite
sides which are each open for operator access therein.
7. A popper as in claim 1 wherein said cabinet has two opposite
sides which are each open for operator access therein.
8. A popper as in claim 1 wherein said inlet comprises a vapor oil
baffle.
9. A popper as in claim 8 wherein said plurality of filtration
stations comprises first and second filters, sequentially disposed
in said passage downstream of said baffle, said first filter
filtering salt and grease particulates from said effluent after
passage thereof past said baffle and said second filter filtering
smoke particulates from said effluent downstream of said first
filter.
10. A popper as in claim 1 wherein said inlet of said filter
passage is unconnected from said kettle and said kettle top.
11. A popper as in claim 1 wherein said kettle top is moveable
relative to said inlet.
12. A popcorn popper for use in an area, comprising: a cabinet
including a popcorn receiving chamber having a top wall; a popcorn
popping kettle assembly including a kettle and a kettle top located
entirely within said popcorn receiving chamber and spaced from the
top wall thereof; a filter passage with an inlet located in an
upper portion of said popcorn receiving chamber below the top wall,
said inlet being in fluid communication with said kettle assembly;
a plurality of filtration stations in said passage; and a blower
operably coupled to said passage for sucking vapor effluent from
said kettle into said inlet and through said filtration stations;
said blower having a discharge outlet for discharging filtered
vapor effluent into said area located outside of said cabinet.
13. A popper as in claim 12 wherein the blower is located entirely
outside of the popcorn receiving chamber.
14. A popper as in claim 12 wherein said passage inlet comprises a
vapor oil separating baffle for receiving oil laden vapor and
separating therefrom oil therein.
15. A popper as in claim 14 wherein a first filtration station
downstream of said baffle in said passage comprises a particulate
filter for removing grease and salt particles from said
effluent.
16. A popper as in claim 15 wherein a second filtration station
downstream of said first filtration station in said passage
comprises a filter for removing smoke components from said
effluent.
17. A popper as in claim 12 wherein said kettle has a lid and
further including an oil baffle in said lid, said baffle being open
for selective passage of a fire suppressant agent into said
kettle.
18. A popper as in claim 12 wherein said inlet of said filter
passage is unconnected from said kettle and said kettle top.
19. A popper as in claim 12 wherein said kettle top is moveable
relative to said inlet.
20. A popcorn pass-through popcorn popper for use in an area,
comprising: a cabinet having two opposite open sides providing
access to a popcorn receiving chamber having a top wall; a popcorn
popping assembly including a kettle and a kettle top located
entirely within said popcorn receiving chamber and spaced from the
top wall thereof; a vapor effluent treating passage for filtering
vapors issuing from the popping of popcorn in said kettle assembly
during a popping operation and for discharging filtered effluent
into the environment in which said popper is located; an inlet of
said vapor effluent treating passage being disposed in an upper
portion of said popcorn receiving chamber and below the top wall,
said inlet being in fluid communication with said kettle assembly;
a plurality of filtration stations in said passage; and a blower
for sucking effluent into said inlet and through said passage so as
to discharge filtered effluent into said area located outside of
said cabinet.
21. A popper as in claim 20 wherein said passage and blower are
disposed within said cabinet.
22. A popper as in claim 20 wherein the blower is located entirely
outside of the popcorn receiving chamber.
23. A popper as in claim 20 wherein said blower has an outlet
disposed for discharging effluent from said passage into said
cabinet.
24. A popper as in claim 20 wherein said inlet of said vapor
effluent treating passage is unconnected from said kettle and said
kettle top.
25. A popper as in claim 20 wherein said kettle top is moveable
relative to said inlet.
Description
CROSS-REFERENCE
[0001] The present application is a continuation application of
co-pending U.S. Ser. No. 13/560,433, filed Jul. 27, 2012, which is
a continuation application of U.S. Ser. No. 13/004,168, filed Jan.
11, 2011, now abandoned, which is a continuation application of
U.S. Ser. No. 10/560,540, filed Feb. 28, 2005, now U.S. Pat. No.
7,874,244, issued on Jan. 25, 2011, which is a Section 371 of PCT
International Application No. US05/06478 filed Feb. 28, 2005, which
claims the benefit of the filing date of U.S. provisional patent
application Ser. No. 60/548,538 entitled "SELF-CONTAINED POPCORN
POPPER", filed in the U.S. Patent and Trademark Office effective
Feb. 27, 2004, the disclosures of which are incorporated herein by
reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] This invention relates to popcorn poppers and more
specifically to open or pass through poppers.
[0003] In the past, particularly with commercial or industrial
capacity popcorn poppers used, for example, in theaters or other
facilities where large quantities of popcorn are popped in
sequential large batches and sold, it is common to install a large
capacity popper in a custom installation with appropriate effluent
ducting and fire suppression systems interconnected to the popper
to meet a variety of codes and safety requirements.
[0004] Local and state building codes in the United States and
elsewhere in the world require ventilation hoods over cooking
equipment that produce grease laden vapors. Regulation,
specification and code producing agencies in the United States
include the National Fire Protection Association (NFPA), the
American National Standards Institute (ANSI) and the Environmental
Protection Agency (EPA) (see 202 Test Standards).
[0005] Large popcorn machines, typically found in movie theaters,
are occasionally classified by local and state building inspectors
as cooking equipment capable of producing sufficient grease laden
vapors to require a ventilation hood. Sometimes in the United
States, these are referred to as "Class 1" devices, requiring a
hood with external discharge through ducting, a fire suppression
system and outside make-up air.
[0006] Other systems or devices where a hood may exhaust into the
area or space where the cooker is located are referred to as "Class
2" devices, but in these the hoods are not integrated into the
cookers or devices.
[0007] While design and installation of a popper and its associated
ducting, hoods and fire suppression systems can be accomplished
easily in new facilities, the popcorn operation poses certain
difficulties and expenses in new facilities and these problems are
even worse in remodeling or attempted relocation or retrofitting of
poppers in existing facilities. Such problems exist for both such
"Class 1" and "Class 2" systems.
[0008] A typical ventilation system for a "Class 1" device includes
an exhaust hood or canopy, ductwork, fan system, and a means of
providing adequate makeup air as the "contaminated" air is
exhausted from the building. There is a significant construction
cost associated with this type of system for new construction and
particularly for remodel projects where ductwork must penetrate
existing structures.
[0009] For example, where such poppers produce significant amounts
of steam or oil vapors, laden with solid articulates, which must be
vented or captured, the installation of such a popper requires hood
or ducting work which, in a large building, could add cost in the
range of $70,000 or more to accommodate the popper. This cost
applies not only to new installations, but to retrofits or
remodeling. And where any retrofit or remodeling involves
relocation of a popper or popper location, significant extra costs
are incurred by the necessary ducting and fire suppression systems
required by codes.
[0010] Moreover, when the popper is of the "pass-through" or "open"
variety, where the chamber receiving popped corn directly from the
kettle is open, for access from both sides, for example, and has no
containing side wall, treatment of the oil and steam vapors and
vapor borne solid particulates within such widely open cabinets is
even more problematical.
[0011] An alternate approach is to employ a recirculating system
where the contaminated air is captured, filtered and returned to
the room or environment surrounding the popper (such as in a "Class
2" type device). Current UL/ANSI regulations define design
requirements, test procedures and offer a listing service for those
products under category "KNLZ".
[0012] Such regulations cover cooking equipment for commercial use,
such as pressurized deep fat fryers and other appliances for use in
commercial kitchens, restaurants or other business establishments
where food is prepared. Each appliance covered in this category has
an integral recirculating air system to limit the emission of
grease-laden air from the cooking process to the room ambient
within the limit of 5 mg/m.sup.3. Hood location, structure and
placement is of concern and must be dealt with in coordination with
popper installation.
[0013] Nevertheless, popcorn poppers of high capacity for
commercial installations typically generate more oil and
steam-laden vapors and solid particulates, including smoke, than
can be handled by known recirculating or self-contained popping
systems. Such current high capacity poppers have thus required
hooding and/or external ducting to comply with present codes.
[0014] Accordingly, it is desired to provide a large capacity
popcorn popper, preferably of the open or pass-through
configuration, which is wholly self-contained without any need for
extraneous duct work or hoods, which can be placed at any location
in a facility without regard to new or existing duct work, and yet
which contains and captures oil and steam vapors and vapor borne
solid particulates with an efficiency well within the various
applicable codes, and which has a self-contained fire suppression
system, also within applicable fire codes.
[0015] It is one objective of the invention to provide a popcorn
popper having a production capability sufficient for a commercial
installation such as in a theater, and which can be operated within
applicable safety and building codes but without conducting oil and
steam vapor or vapor borne solid particulates externally of the
popper.
[0016] It is a further objective of the invention to provide an
improved, large capacity popcorn popper which is self-contained and
can be operated without external ducting for oil and steam vapor
and vapor borne solid particulates, heretofore required for such
capacity poppers in similar installations.
[0017] A yet further objective of the invention is to provide a
large capacity popcorn popper for use in retrofitting or remodeling
a commercial facility, such as a theater, without interconnection
of such popper to any external duct work from said popper.
[0018] A yet further objective of the invention has been to provide
an improved popcorn popper to facilitate installation of popcorn
poppers in new and remodeled commercial facilities independently
and separately of any exhaust ducting.
[0019] A further objective of the invention has been to provide an
improved self-contained popcorn popper capable of internally
separating from any effluent therefrom, such oil, vapor or vapor
borne particulates as would violate applicable building or safety
codes.
[0020] A further objective of the invention has been to provide an
improved popcorn popper with improved filtration of vapor and
particulate emissions.
[0021] A further objective of the invention has been to provide a
high capacity popcorn popper without requiring external ducting nor
separate hooding with exhaust into surrounding areas.
[0022] A further objective of the invention has been to provide a
self-contained, high-capacity popcorn popper which discharges
effluent into the area surrounding the popper but with less than 5
milligrams of particulate per cubic meter of effluent
discharged.
[0023] Prior to the invention, there were difficulties in meeting
these objectives.
[0024] In a pass-through high capacity popper, there are large open
access areas on both sides in and to the bin or storage area where
warm popped corn is stored. Effluents issuing from the kettle and
the bin must be captured before escaping into the surrounding
environment, but with the open pass-through configuration, it is
difficult to meet strict discharge standards such as no more than 5
mg per cubic meter (5 mg/m.sup.3) of particulates in the overall
effluent discharged from the operation.
[0025] There are variations in the rate and pattern of discharged
or untreated effluents from the operational stages of popping,
dumping, storage and retrieval of popcorn. Some of these stages are
attended by more rapid excess of steam and vapor, such as when the
kettle lid is forced open by the popping popcorn, or when the
popcorn is dumped from the kettle to bin, than a slower exit of
steam and vapor from other operational stages. Moreover, varied
effluent patterns and vortices occur during the operational
processes. It is difficult to effectively capture and treat
significantly all effluent from such varied operational stages and
events.
[0026] There is a complex relationship between the nature of
effluent, including volume, particulate size and total particulate
capture on the one hand and reasonable filtration life and
maintenance on the other. Too much air flow capacity can overdrive
the effluent, driving otherwise filterable particulates through a
filter for that particulate stage, prematurely, or can clog a
filter system. Insufficient flow capacity may be insufficient to
capture and entrain effluent from the open areas or sides of the
popper during major effluent discharging events.
[0027] There are difficulties in overall design of a large capacity
popper capable of both new and remodel installation, while
providing self-contained effluent treatment without external
ducting in both applications.
[0028] The provision of a fully self-contained popper without
external effluent ducting raises fire suppression concerns in the
areas of the kettle, popcorn storage area or bin, popping oil
storage area and with the self-contained effluent treatment
areas.
[0029] A further objective of the invention has been to provide a
large capacity popcorn popper having "pass-through" or open side
access to the popping area, yet having a fully self-contained vapor
and particulate handling apparatus allowing use of the popper at
full capacity without external ducting of vapor or particulate
effluent.
SUMMARY OF THE INVENTION
[0030] To these ends, the invention contemplates an improved large
capacity popcorn popper preferably of open or pass-through
configuration and having a self contained vapor and particulate
filtering apparatus which creates a flow of vapor popping and
storage effluent into and through a series of traps and filters and
emits an effluent cleaned of oil and particulates in a degree
sufficient to meet applicable emission codes, i.e. within maximum
of 5 milligrams of particulate solids produced per cubic meter (5
mg/m.sup.3) of flow for eight hours of a production cooking cycle.
The processed effluent can be exhausted into the ambient space or
environment in which the popper is located, without external
ducting or hooding of any sort. And a fire suppression system
integral with the popper is operable to suppress fires in the
popper, including oil fires in the popping kettle.
[0031] Accordingly, the popper according to the invention can be
used in any suitable location without the provision of associated
duct work and without the necessity to be connected to or slaved to
any existing or new duct work, hoods or fire suppression system.
Renovations of a facility without regard to cost of popper ducting
or exhaust is thus possible, as is original architectural planning
without any regard to popper ducting positioning or associated
costs.
[0032] One embodiment of the invention includes an open or
"pass-through" popcorn receiving chamber and preferably for popping
popcorn and dumping popped popcorn therein, from where the popped
popcorn can be accessed for service to purchasers, or in which it
can be stored.
[0033] A plenum or effluent passage has an entry end or inlet above
the bin proximate the kettle. A plurality of filtration stations
comprising oil baffles and filter units are provided within a vapor
effluent path through the passage. These stations treat or process
the vapor effluent drawn to the suction side of a blower which
discharges cleaned air or effluent. The blower and suction inlet is
preferably located in the bottom of the popper cabinet (but may be
elsewhere) and is sufficient to draw vapor produced by popcorn
popping and popped popcorn into the passage and through the
filtration stations for cleaning, with no significant untreated
vapor escaping from the popper.
[0034] A particular series of selected baffles and filters are used
to coordinate effluent flow sufficient to capture all significant
effluent for treatment, yet not overdrive or clog filter operation.
In particular, a large matrix pass-through baffle plate of
staggered baffles is first encountered by the effluent where oil
impinges on and "plates out" on the baffles, draining to a removal
pan. The oil-cleaned effluent then flows to a second filtration
stage comprising a high capacity filter sufficient to remove grease
and salt particles from the effluent, but insufficient to remove
smoke, containing other smaller particulates. The effluent then
flows to a final filtration station which is preferably a high
efficiency particulate arrester or "HEPA" type filter which
captures the smaller smoke particles or components.
[0035] While the blower in the cabinet bottom is preferably rated
at approximated 1200 CFM, the effluent velocity flow is kept below
500 FPM, and is thus insufficient to drive selected particles
through the filters designed for those particle stages. Premature
filter clogging is minimized or eliminated and the flow, filter
sizes and filter life between cleaning and/or replacement is
enhanced.
[0036] The baffles and filters are removable for replacement or
cleaning. Sensors in the vapor path within the effluent passage
sense pressures, indicative of flow, and signal when it is time to
replace or clean the baffles or filters as a function of their
efficiency, derated by pressure changes in the flow. Fail-safe
sensors are electronically coupled to prevent popping once the
sensed efficiencies drop below a predetermined level.
[0037] A fire suppression system is self-contained within the
popper for suppressing any sensed fire therein. The kettle top is
provided with a porosity sufficient to admit fire suppressant in
the event of a kettle fire, and undesired fire is contained within
the popper.
[0038] Through the use of any suitable electronic controls, and
signals, a popping operation can be carried out automatically, with
only acceptable effluent discharged, and without any effluent
discharge beyond the popper environment or into any exhaust duct
being necessary.
[0039] Such popper can thus be installed in a facility independent
of and without regard to any exhaust ducting, saving significant
cost in original or remodel construction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] These and other objects and advantages will become readily
apparent from the following written description and from the
drawings, in which:
[0041] FIG. 1 is a perspective view of the invention;
[0042] FIG. 2 is an elevational view in partial cross-section
showing the flow path of vapor and effluent and a portion of a fire
suppression system;
[0043] FIG. 3 is an enlarged cross-sectional view of an upper
portion of the popper of FIGS. 1 and 2;
[0044] FIG. 4 is a layout view of a control panel of the popper of
FIGS. 1 and 2;
[0045] FIG. 5 is an illustrative view of a portion of the fire
suppression system of the popper of FIGS. 1 and 2;
[0046] FIG. 6 is an illustrative perspective view of an upper
portion of the popper of FIGS. 1 and 2; showing a filter access
door open;
[0047] FIG. 7 is an illustrative perspective view of the popper of
FIGS. 1 and 2 but showing the baffle plate and filters removed;
[0048] FIG. 8 is another plan view of a kettle top according to one
aspect of the invention; and
[0049] FIG. 9 is a perspective view of the top of FIG. 8
illustrating the function of baffle kettle top.
DETAILED DESCRIPTION OF THE INVENTION
[0050] More particularly, a popper 10 (FIG. 1) comprises an upper
cabinet 12 having a kettle 14 for popping and discharging popped
popcorn into the popcorn bin 16. Front side 18 and rear side 20 of
cabinet 12 are open. Thus, bin 16 is accessible by operators from
both the front and rear sides. The open sides provide operator
access preferably to both the bin and to the kettle.
[0051] Popper 10 includes the upper cabinet portion 12 and a lower
cabinet portion 22 having a vented door 24 and storage doors 26, 28
behind which components of a fire suppression system can be
disposed.
[0052] A control panel 30 (FIGS. 1 and 4) is disposed preferably on
upper cabinet portion 12, or in any suitable location.
[0053] Kettle 14 is any suitable popcorn popping kettle capable of
preferably popping large batches of popcorn (not shown) for
discharge into bin 16. Kernel charges or loads of 28 to 66 ounces
of unpopped popcorn (for example) are typical for placement into
kettle 14 for popping. In this regard, it will be appreciated that
popper 10 is preferably of commercial, high production capacity for
delivering successive batches of popped popcorn from load sizes
such as this. A popping cycle of such a load can produce, for
example, four pounds of steam and oil vapor and associated popping
particulates from kettle 14 for each popping cycle. Poppers of
other capacities, greater or lower, can benefit from the
invention.
[0054] Turning now to FIG. 2, the invention is further seen in
elevational cross-section. Oil baffle or trap 32 defines a vapor
effluent inlet for receiving an intake of steam and oil laden
vapor, and vapor borne particulates, from a cooking cycle of
popcorn in kettle 14 and from bin 16. The flow of vapor effluent
through the popper and filtration passage of popper 10 is
illustrated by the arrows A in solid and dotted lines in FIGS. 1-3
for illustration. Clean air exits the popper 10 through door 24 as
illustrated by arrow B, FIGS. 1 and 2.
[0055] Baffle trap 32 comprises a plurality of staggered baffles
33, 35 defining a tortuous path for vapor flow wherein oil droplets
are removed from the effluent vapor flow by impingement onto the
baffle and flow to collection tray 36. The oil baffle or trap 32 is
a "coarse" filter and includes a baffle plate 34 and a catch tray
36. Plate 34 comprises sets of a plurality of elongated baffles 33,
35 (FIG. 3) in offset fashion. Baffles 33 in a first set are
slightly spaced apart with baffles 35 in a second set oriented in
line with the spaces in the first set, so the vapor path is
tortuous. When oil laden vapor flowing through baffle/trap 32
engages the baffles 33, 35, oil collects and dribbles down to catch
tray 36, which can be removed as shown in FIG. 3.
[0056] Baffle or trap 32 comprises a passage inlet for vapor
effluent (arrows A) through a vapor cleaning or filtering path P
defined by passage 40 and terminating in blower 42 having its
suction side 44 connected to passage 40 and its outlet side 46
disposed to blow effluent of cleaned or processed air or vapor out
of the vented door 24.
[0057] Downstream of baffle or trap 32 is a suitable first filter
48 defining a first filtration station downstream of baffle 32.
This filtration station comprises a medium filter, referred to as a
"bag" filter, preferably comprising a fiberglass box filter of
about 80% efficiency relative to the cleaning of steam and oil
vapor. Such a filter is, for example, filter Model R-803-PH
purchased from Total Filtration Systems of Cincinnati, Ohio.
[0058] From filter 48, the vapor effluent (A) flows through a
suitable second filtration station comprising filter 50. One such
suitable filter is preferably a hypoallergenic filter 50 referred
to as a "HEPA" filter, which can be purchased from Total Filtration
Systems of Cincinnati, Ohio, Model VPL-0395DOP. This final filter
cleans the vapor effluent of smoke particulates or components.
[0059] From filter 50, the now cleaned effluent passes through
passage 40 into the intake side 44 of blower 42 and through the
outlet 46 of blower 42 where the processed air, significantly
cleaned of oil and of particulates, is exhausted outside the popper
as illustrated by the arrow B into the environment in which popper
10 is situated. Blower 42 can actually discharge the cleaned
effluent into a lower chamber in the lower portion 22 of the
popper, from where it is emitted into the surrounding environment
through a vented door 24 (arrow B).
[0060] For illustration, the filters 48, 50 and baffle 32 are shown
removed outside the popper 10 in FIG. 7 or cleaning or replacement.
A door 38 in passage 40 provides access to the interior of the
passage for replacement of filters 48 and 50.
[0061] A fire suppression system 56 (FIG. 5) is comprised of a fire
suppression agent tank 58, a propellant (such as CO2), tank 60,
both disposed in a storage area behind doors 26, 28, as shown in
FIG. 2, and a plurality of suppression agent delivery conduits 62
terminating in agent dispensing nozzles 64 disposed in appropriate
positions to deliver suppression agent to a fire occurring in
varied locations of popper 10. Such an array of conduits and
nozzles is illustrated in FIG. 5, while a variety of nozzles 64,
64A are shown in FIG. 2.
[0062] A fire-sensing and suppression activity trigger system of
any suitable variety can be used to initiate fire suppression on
sensing a fire. One such system is the well-known "Ansul" System,
available from Ansul Incorporated of Marinette, Wis. Such fire
suppression systems can be seen in the Ansul webpage at
www.ansul.com, and is incorporated herein by reference, although
not necessary to an understanding of the invention herein.
[0063] Such system typically operates in a well known fashion on
the basis of a tensioned cable and a plurality of fusible links 66
(FIG. 5) serially disposed in the cable. Heat can destroy a link,
releasing cable tension and such release triggers or activates the
fire suppression system to discharge suppression agent in a well
known manner. A plurality of links are used in appropriate
locations.
[0064] Returning to the flow of vapor in the direction of arrows A,
sensors (not shown) are disposed in passage 40 to sense the
presence or absence of any of the baffles or filters 32, 48 or 50.
If any of these baffles or filters are absent, or not seated in a
way so their presence is indicated by the dedicated server, an
appropriate control prevents operation of the popper 10. In this
way, appropriate vapor cleansing is assured.
[0065] It will be appreciated that blower 42 is preferably disposed
in the lower portion 22 of cabinet 12, leaving the upper area of
popper 10 free of blower structure, rendering it easier to handle
air flow in the upper portion of cabinet 12. In this regard, blower
42 produces preferably about 1200 cubic feet per minute air flow.
Through control of the blower size of passage 40 and parameters of
the baffle 32 and filters 48, 50, effluent flow is preferably
limited to 500 feet per minute or below. This dynamic produces
sufficient suction to create a flow of substantially all vapor
effluent produced from kettle 14 and from discharged popcorn in bin
16 into passage 40, and through baffle 32 and filters 48, 50. This
is important in view of the open, pass-through sides 18, 20 of
cabinet 12 through which vapors might otherwise escape.
[0066] Moreover, leaving the top of the upper cabinet 12 free of
blower structure and concerns reduces its bulk and allows popper 10
to be located in areas without concerns of extraneous or
unnecessary dome or hood sizes. Blower 42 and passage 40 could
otherwise be located in other disposition and location in or on the
popper 10.
[0067] Also, wing panels 54 (FIG. 1) can be used to help define
flow around kettle 14 toward baffle/trap 32.
[0068] Another feature of the invention includes monitoring of the
vapor flow as a function of filter efficiency to confirm the vapors
and particulars are being cleaned to the design specifications.
This is accomplished by pressure sensors disposed within passage 40
to sense the pressure of effluent flowing therein. If the design
flow capacity suffers a reduction, such as a 25% reduction in flow,
for example, as a function of flow pressure change, indicating a
clogged filter, the popping system is electronically disabled,
pending filter replacement or cleaning.
[0069] To this end, one pressure sensor 70 (FIG. 2) senses a flow
pressure decrease indicating the system is approaching a 25%
reduction in flow capacity, warning a user to replace or clean the
filters. A second pressure sensor 72 is set to indicate a higher
limit reduction flow, for example, as a function of a higher
pressure at which time a current popping cycle continues, but a
signal is generated and further popping cycles are blocked until
filters are replaced or cleaned. Thus, the invention provides both
a fail safe to disable popping where combined operation may
overpower the vapor processing parameters and an earlier warning
that efficiency is sufficiently reduced to warrant baffle or filter
cleaning or replacement.
[0070] Sensors can be placed selectively upstream or downstream of
each filter 48, 50 to indicate the status of each filter.
[0071] Status indicators, such as lights are used on panel 30 (FIG.
4) to indicate that the filters are in place and to indicate filter
status. Status lights also indicate the need to check or to service
(replace) filters.
[0072] Another feature of the invention includes suppression agent
nozzle 64A (FIG. 2) located above kettle 14. It is important in
fire suppression systems that suppression agent is directed onto
the fire at its source. In popping popcorn, hot oil is used in
kettle 14. If that oil in kettle 14 ignites, such as during popping
when the kettle is covered with a top, it is necessary to apply
suppression agent to the fire in the kettle. But the typical kettle
is blocked by the top.
[0073] The invention contemplates a grid-like, or porous top, or
other baffle-modified top having a plurality of baffles disposed to
prevent oil from spattering out of the kettle, but having
sufficiently open interstices through the baffles of the top to
allow suppression agent from nozzles such as 64A to be introduced,
in the advent of sensed (as desired) excess heat, fire, into the
kettle 14 to suppress any fire therein. Escape of heavy oil drops
or particulates is thus prevented while, at the same time,
sufficient ingress of necessary fire suppression agent is
facilitated.
[0074] Moreover, such a kettle top provides another benefit, and
that being the performance of allowing the smoke and other
effluents of the cooking process to vent from the kettle as they
are created, rather than all at once (such as when the popped corn
is dumped), which could overload the filtration provided or
discharge unfiltered effluent outside the popper. Thus, the kettle
top acts as an initial baffle or screen, upstream of baffle 32, and
at the kettle to prevent larger oil droplets and particulates from
entering the effluent flow to be filtered in passage 40 allowing
oil to drop back into kettle 14. Also, the porous top does not fan
the cooking effluents when popped corn is dumped from the kettle,
which could push smoke or vapor into areas of the cabinet where it
would not be readily captured in the filtration flow.
[0075] The kettle top can be of any suitable configuration,
preferably defining a porous or preferably tortuous path for egress
of smoke and vapor and, at the same time, ingress of any necessary
fire suppression agent.
[0076] One form of baffle-modified kettle top is shown in FIGS. 8
and 9. In FIG. 8, a kettle top has a central brace 80 of any
suitable and typical configuration which may support any rotor or
other kettle device as is well known. The kettle lid comprises a
pivoted front lid 81 and a pivoted rear lid 82. Both are pivoted to
member 80. Each lid 81, 82 includes a cut-out 83, 84 of any
suitable shape, here shown as rectangular. Disposed beneath each
cut out 83, 84 and welded to the underside of lids 81, 82 are
respective baffles 85, 86.
[0077] Each baffle is preferably similar, only one being shown in
FIG. 9, that is baffle 85 for front lid 81.
[0078] Baffles 85, 86 are "W" shaped as shown in FIG. 9. The edges
87, 88 of the baffles do not touch the underside of the lids. As
well, ends 89, 90 of the baffles 85, 86 are open, while the
elongated center apex of each baffle is secured as by spot welding
to the underside of the respective lids 81, 82.
[0079] In a normal popping process, oil and oil laden vapor contact
the underside of the baffles 85, 86. Oil and oil droplets in the
vapor impact on the underside of the baffles 85, 86 and fall back
into the kettle (illustrated in FIG. 9), while some oil-laden vapor
and perhaps smoke and steam escape. This escape path is around the
ends 87, 88 of the baffles 85, 86 and through the open ends at 89,
90.
[0080] If it is necessary to put out a fire in the kettle, an
appropriate fire suppressant agent is emitted from a nozzle such as
at 64A (FIG. 2) onto the kettle lids 81, 82 and particularly onto
baffles 85, 86. This agent is introduced into the kettle over
baffle edges 87, 88 and through ends 89, 90 at each end of each
respective baffle 85, 86 in each lid 81, 82. The wide arrows in
FIG. 9 demonstrate this flow. Fire in the kettle is thus
effectively handled.
[0081] Accordingly, the invention provides an open, pass-through
cabinet in a totally self-contained popcorn popper, eliminating the
need for connection to separate ducting, hoods and venting for
vapor effluent and steam.
[0082] The popper need not be limited in disposition to a fixed or
design footprint in any new or remodeled facility, since it is free
of duct work or hood connection, and of exterior or separate fire
suppression trigger cables and the like.
[0083] The invention is useful in open-sided pass-through
configurations as shown, in closed-sided configurations and in one
open side configurations as well and particularly in commercial or
high-capacity poppers popping kernel loads of 28 to 66 ounces, for
example, in a single batch. Also, it can be used for poppers of the
pivoted kettle variety shown herein, or in poppers where the kettle
is pedestal mounted.
[0084] As well, the invention provides a popcorn popper of
self-contained configuration, regardless of the orientation of
filter passage and blower location, capable of emitting effluent of
no more than 5 milligrams of particulate per cubic meter of
effluent into the area within which the popper is placed.
[0085] The invention thus comprises the first known high-capacity
popcorn popper where the entire filtration system is self-contained
within the popper itself
[0086] It will be appreciated that among its other features and
advantages, the invention includes, singly and in variable
combination: filter interlocks; filter replacement warnings as a
function of filter performance measured by flow pressure; popping
cut-off upon degradation of filter performance; a pre-filter stage
baffle/trap 32 with oil catching tray; capture of all vapor, smoke
and cooking effluent for processing; an open, pass-through cabinet
defining in part a popped corn receiving bin; a gridded or tortuous
path kettle top for egress of smoke and vapor and ingress of any
necessary fire suppression agent; self-contained popper total
placement freedom without operation ties to separate hoods, outside
ducting or separate fire suppression systems; and passes current
U.L., EPA and other standards for self-contained food cooking units
producing oil vapors.
[0087] The popper of the invention can simply be put to use in any
facility with no outside venting, ducting or separate hoods or fire
suppression, yet still meet applicable codes. Initial facility
design and remodeling are facilitated with reduced costs.
[0088] The popper 10 can accommodate variation in loads of kernels
to be popped, and popping of corn for both sugar and salt
applications and the like.
[0089] Appropriate solid state controls, computers, programmable
logic controllers (PLCs), CPUs or the like can be used to control
the functions, sensors, interlocks, suppression systems, cooking,
dumping, oil pumping, batch size, batch type, lights, kettle drive,
kettle heat, kettle dump and other parameters of the popper 10, and
such as described in U.S. Pat. Nos. 6,829,982; 6,752,071;
6,726,945; 6,672,201 and 6,135,011, each of which is incorporated
herein by express reference.
[0090] These and other advantages and modifications will be readily
apparent to those of ordinary skill in the art without departing
from the scope of the invention and applicant intends to be bound
only by the claims appended hereto.
* * * * *
References