U.S. patent application number 15/899289 was filed with the patent office on 2018-06-21 for chilled product post-processing apparatus and methods.
This patent application is currently assigned to BlendTec, Inc.. The applicant listed for this patent is BlendTec, Inc.. Invention is credited to Evan J. Bauer, David Q. Bytheway, Thomas D. Dickson, JR., Joseph O. Jacobsen, Bradley S. Maxfield, David J. Throckmorton.
Application Number | 20180168184 15/899289 |
Document ID | / |
Family ID | 57441433 |
Filed Date | 2018-06-21 |
United States Patent
Application |
20180168184 |
Kind Code |
A1 |
Jacobsen; Joseph O. ; et
al. |
June 21, 2018 |
CHILLED PRODUCT POST-PROCESSING APPARATUS AND METHODS
Abstract
A method of processing a chilled food product includes providing
a product in a storage container, wherein the product has a frozen
portion and a non-frozen portion in the storage container, and the
frozen portion has a granular size. The method also includes mixing
the frozen portion of the product with the non-frozen portion of
the product within the storage container, flowing the frozen
portion and non-frozen portion into contact with a shearing
apparatus, and shearing at least the frozen portion with the
shearing apparatus, thereby reducing the granular size of the
frozen portion. This method and similar systems and machines may
refine and process chilled food products such as smoothies and
slushes to have a smoother and more even consistency.
Inventors: |
Jacobsen; Joseph O.;
(American Fork, UT) ; Throckmorton; David J.;
(Mapleton, UT) ; Dickson, JR.; Thomas D.; (Orem,
UT) ; Bytheway; David Q.; (Springville, UT) ;
Maxfield; Bradley S.; (Spanish Fork, UT) ; Bauer;
Evan J.; (Holladay, UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BlendTec, Inc. |
Orem |
UT |
US |
|
|
Assignee: |
BlendTec, Inc.
Orem
UT
|
Family ID: |
57441433 |
Appl. No.: |
15/899289 |
Filed: |
February 19, 2018 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
14730549 |
Jun 4, 2015 |
9894912 |
|
|
15899289 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A23G 9/281 20130101;
A23G 9/12 20130101; A23G 9/045 20130101 |
International
Class: |
A23G 9/12 20060101
A23G009/12; A23G 9/04 20060101 A23G009/04 |
Claims
1. A method of processing a chilled food product, the method
comprising: providing a product in a storage container, the product
having a frozen portion and a non-frozen portion in the storage
container, the frozen portion having a granular size; mixing the
frozen portion of the product with the non-frozen portion of the
product within the storage container; flowing the frozen portion
and non-frozen portion into contact with a shearing apparatus;
shearing at least the frozen portion with the shearing apparatus,
thereby reducing the granular size of the frozen portion.
2. The method of claim 1, wherein flowing the frozen portion and
non-frozen portion into contact with the shearing apparatus
comprises moving at least some of the frozen portion and at least
some of the non-frozen portion from a first area of the storage
container into a second area of the storage container.
3. The method of claim 1, wherein flowing the frozen portion and
non-frozen portion into contact with the shearing apparatus
comprises moving at least some of the frozen portion and at least
some of the non-frozen portion from the storage container into a
shearing chamber.
4. The method of claim 1, further comprising continuously shearing
the product using the shearing apparatus.
5. The method of claim 4, wherein the continuous shearing is
performed only in response to a request for the product.
6. The method of claim 1, further comprising shearing a discrete
amount of the product by the shearing apparatus in response to a
request for the product.
7. The method of claim 6, further comprising adding an additional
ingredient into the discrete amount of the product.
8. The method of claim 1, wherein the product is at least partially
frozen by moving non-frozen portions of the product into contact
with a refrigerated element in the storage container.
9. The method of claim 1, wherein the product is at least partially
frozen by refrigerating the storage container sufficient to freeze
at least some of the non-frozen portion of the product.
10. The method of claim 1, wherein mixing the product comprises
substantially evenly distributing the frozen portion among the
non-frozen portion of the product.
11. The method of claim 1, wherein the shearing apparatus at least
partially rotates in a vertical plane to shear the frozen
portion.
12. The method of claim 1, wherein the shearing apparatus at least
partially rotates in a horizontal plane to shear the frozen
portion.
13. The method of claim 1, further comprising dispensing the
product after being sheared by the shearing apparatus.
14. A method of processing a food product stored in a storage
container, the method comprising: providing a storage container in
fluid communication with a blending apparatus, wherein a food
product stored by the storage container is dispensable from the
storage container by flowing into the blending apparatus and then
out of the blending apparatus through a dispenser; receiving a
request for the food product; enabling flow of the food product
into the blending apparatus; engaging the blending apparatus,
thereby shearing the food product in the blending apparatus;
enabling flow of the food product through the dispenser.
15. The method of claim 14, wherein receiving a request for the
food product comprises detecting operation of the dispenser by a
user.
16. The method of claim 15, wherein operation of the dispenser by a
user engages the blending apparatus.
17. The method of claim 14, wherein shearing the food product in
the blending apparatus comprises at least partially breaking down
the food product into particles smaller than particles of the food
product in the storage container.
18. The method of claim 14, wherein enabling flow of the food
product into the blending apparatus comprises operating a mixing
apparatus in the storage container.
19. The method of claim 14, wherein enabling flow of the food
product into the blending apparatus comprises inducing flow of the
food product by gravity or fluid pressure.
20. A method of processing a food product, the method comprising:
providing a storage container containing a food product and a
rotor-stator assembly connected to the storage container, the
rotor-stator assembly having a rotor, a stator, and an exit
opening; moving the food product into contact with a horizontal
surface of the rotor; rotating the rotor to direct the food product
along the horizontal surface to a position under an angled surface
of the stator; shearing the food product between the angled surface
of the stator and an angled surface of the rotor, the angled
surface of the rotor being positioned radially outward relative to
the horizontal surface; advancing the food product to the exit
opening of the rotor-stator assembly.
21. The method of claim 20, further comprising advancing the food
product between the stator and a vertical surface of the rotor
before advancing the food product to the exit opening.
Description
RELATED APPLICATION
[0001] This is a divisional of U.S. patent application Ser. No.
14/730,549, filed on 4 Jun. 2015, now pending, the disclosure of
which is incorporated, in its entirety, by this reference.
TECHNICAL FIELD
[0002] The present disclosure is generally directed to machines and
methods used to make chilled slush, smoothie, granita, and related
products, and the disclosure particularly relates to systems and
methods for smoothing the product dispensed from these
machines.
BACKGROUND
[0003] Smoothies, slushes, and related chilled or icy products are
enjoyed by consumers worldwide. Generally, these products are made
using one of two popular methods. In the first method, pellets or
cubes of ice may be added to a mixture of other ingredients and
then blended in a blending jar using a blending blade. This process
breaks up the ice into smaller, smoother granules and thoroughly
mixes all of the ingredients into a smoothie consistency that is
based primarily on variables within the control of the operator,
such as the properties of the ingredients and ice and the blending
mode and duration.
[0004] Due to the strain on the blender, consistently blending hard
ingredients including ice and frozen fruit requires
high-performance, expensive blending equipment. In some cases, the
product is prepared in the blender using pumps, wherein at least
portions of the product are pumped into a blending chamber,
combined with ice, and then blended before being dispensed to a
customer's cup. These devices require tubing and pumps for fresh
ingredient supply and to drain out the chamber after blending,
thereby increasing the blending apparatus's cost, complexity, and
difficulty to maintain and clean. In a commercial setting, this
method of preparation also has the drawback of requiring time to
measure and blend ingredients for each batch of product when the
product is ordered, especially since the consistency of the product
quickly deteriorates as the blended ice melts. Thus, new batches of
smoothies or slushes have to be made to order with a delay and wait
time between ordering the product and serving the customer. Some
machines use refrigeration for non-shelf-stable product, but they
are accordingly even more expensive.
[0005] The other popular method of preparing and serving slushes
and smoothies does not require adding ice into other ingredients.
In this method, all ingredients are added to a slush machine (e.g.,
a granita machine) in liquid form, and the product is chilled and
agitated in a hopper. Over time, the product is chilled by contact
with refrigerated surfaces in the hopper, and ice crystals form in
the liquid. Meanwhile, the product is circulated through the hopper
by a mixer (e.g., an auger) and the ice is thereby inhibited from
forming large blocks and is distributed throughout the liquid in
the hopper. To prevent the ice from growing too large over time,
the temperature in the hopper is periodically (e.g., nightly)
elevated to allow the ice to completely melt, and the process
starts over again when the temperature is dropped to an ice-forming
level again.
[0006] The slushy product can be dispensed from one of these
machines on demand, but the ice crystals formed by this method have
inconsistent size and are generally substantially larger than the
crystals made by the blending machines of the first method
described above. Thus, the consistency of the product is not as
smooth as the product from a blending machine. The texture and
flavor are widely regarded as being inferior as well. The machines
still remain popular, however, because they are usually easier to
purchase and maintain than the complex blending devices of the
first method.
[0007] In view of the above, there is a need for improvements in
the methods and apparatuses used to prepare and dispense high
quality chilled products.
SUMMARY
[0008] One aspect of the present disclosure relates to a method of
processing a chilled food product. The method may comprise
providing a product in a storage container, with the product having
a frozen portion and a non-frozen portion in the storage container.
The frozen portion may have a granular size. The method may further
include mixing the frozen portion of the product with the
non-frozen portion of the product within the storage container and
flowing the frozen portion and non-frozen portion into contact with
a shearing apparatus. The method may also comprise shearing at
least the frozen portion with the shearing apparatus, thereby
reducing the granular size of the frozen portion.
[0009] Flowing the frozen portion and non-frozen portion into
contact with the shearing apparatus may comprise moving at least
some of the frozen portion and at least some of the non-frozen
portion from a first area of the storage container into a second
area of the storage container. Flowing the frozen portion and
non-frozen portion into contact with the shearing apparatus may
also comprise moving at least some of the frozen portion and at
least some of the non-frozen portion from the storage container
into a shearing chamber. In some embodiments, the method may
further comprise continuously shearing the product using the
shearing apparatus. The continuous shearing may be performed only
in response to a request for the product.
[0010] In some arrangements, the method may further comprise
shearing a discrete amount of the product by the shearing apparatus
in response to a request for the product. The method may also
comprise adding an additional ingredient into the discrete amount
of the product. The product may be at least partially frozen by
moving non-frozen portions of the product into contact with a
refrigerated element in the storage container. The product may be
at least partially frozen by refrigerating the storage container
sufficient to freeze at least some of the non-frozen portion of the
product. Mixing the product may comprise substantially evenly
distributing the frozen portion among the non-frozen portion of the
product.
[0011] The shearing apparatus may at least partially rotate in a
vertical plane to shear the frozen portion. The shearing apparatus
may also at least partially rotate in a horizontal plane to shear
the frozen portion. The product may be dispensed after being
sheared by the shearing apparatus.
[0012] In another aspect of the present disclosure, a chilled food
product processing machine is provided which may comprise a storage
container configured to hold a supply of fluid ingredients, a
refrigeration apparatus configured to form ice crystals in the
supply of fluid ingredients in the storage container, a fluid
circulating apparatus within the storage container, wherein the
fluid circulating apparatus may be operable to distribute frozen
portions of the supply of fluid ingredients through the storage
container, a blending apparatus connected to the storage container,
wherein the blending apparatus may be operable to shear ice
crystals in the supply of fluid ingredients, thereby reducing an
ice crystal grain size in the supply of fluid ingredients, and a
dispenser opening in the storage container, wherein the supply of
fluid ingredients may be flowable through the dispenser opening to
exit the storage container.
[0013] In this machine, the blending apparatus may extend into the
storage container. The blending apparatus may comprise a rotatable
blending blade. The blending apparatus may comprise a rotor and a
stator. The rotor and stator may be concentrically aligned.
[0014] The machine may have a shearing passage having first and
second end openings in fluid communication with the storage
container, wherein the blending apparatus is configured to shear
ice crystals in the supply of fluid ingredients when the ice
crystals pass through the shearing passage.
[0015] The machine may also have a shearing chamber within a
housing attached to the storage container, wherein the blending
apparatus is operable to shear ice crystals within the shearing
chamber. The shearing chamber may be configured to receive an
additional ingredient prior to shearing ice crystals within the
shearing chamber.
[0016] A surface may be within the storage container, wherein the
refrigeration apparatus is configured to chill the surface within
the storage container to form ice crystals in the supply of fluid
ingredients. The surface may be a cylinder extending into the
storage container.
[0017] The supply of fluid ingredients in the machine may be
flowable to the blending apparatus through the dispenser opening.
The fluid circulating apparatus may be an auger. The refrigeration
apparatus may comprise a chilled surface extending into contact
with the supply of fluid ingredients in the storage container.
[0018] In yet another aspect of the disclosure, a method of
processing a food product stored in a storage container is
provided. The method may comprise providing a storage container in
fluid communication with a blending apparatus, wherein a food
product stored by the storage container is dispensable from the
storage container by flowing into the blending apparatus and then
out of the blending apparatus through a dispenser. The method may
further include receiving a request for the food product, enabling
flow of the food product into the blending apparatus, engaging the
blending apparatus, thereby shearing the food product in the
blending apparatus, and enabling flow of the food product through
the dispenser.
[0019] Receiving a request for the food product may comprise
detecting operation of the dispenser by a user. Operation of the
dispenser by a user may engage the blending apparatus.
[0020] Shearing the food product in the blending apparatus may
comprise at least partially breaking down the food product into
particles smaller than particles of the food product in the storage
container.
[0021] In some embodiments, enabling flow of the food product into
the blending apparatus may comprise operating a mixing apparatus in
the storage container. Enabling flow of the food product into the
blending apparatus may also comprise inducing flow of the food
product by gravity or fluid pressure.
[0022] In another aspect of the disclosure, a method of processing
a food product is provided that may comprise providing a storage
container containing a food product and a rotor-stator assembly
connected to the storage container. The rotor-stator assembly may
have a rotor, a stator, and an exit opening. The method may also
include moving the food product into contact with a horizontal
surface of the rotor, rotating the rotor to direct the food product
along the horizontal surface to a position under an angled surface
of the stator, shearing the food product between the angled surface
of the stator and an angled surface of the rotor, wherein the
angled surface of the rotor is positioned radially outward relative
to the horizontal surface, and then advancing the food product to
the exit opening of the rotor-stator assembly. Some embodiments may
further comprise advancing the food product between the stator and
a vertical surface of the rotor before advancing the food product
to the exit opening.
[0023] The above summary of the present invention is not intended
to describe each embodiment or every implementation of the present
invention. The Figures and the detailed description that follow
more particularly exemplify a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The accompanying drawings and figures illustrate a number of
exemplary embodiments and are part of the specification. Together
with the present description, these drawings demonstrate and
explain various principles of this disclosure. A further
understanding of the nature and advantages of the present invention
may be realized by reference to the following drawings. In the
appended figures, similar components or features may have the same
reference label.
[0025] FIG. 1 is a schematic representation of a system for
processing a chilled food product.
[0026] FIG. 2 is a schematic representation of a system for
processing a chilled food product.
[0027] FIG. 3 is a schematic representation of a system for
processing a chilled food product.
[0028] FIG. 4A is a perspective view of an example machine for
processing a chilled food product.
[0029] FIG. 4B is a top view of the machine of FIG. 4A.
[0030] FIG. 4C is a front view of the machine of FIG. 4A.
[0031] FIG. 5A is a central side section view of the machine of
FIG. 4A.
[0032] FIG. 5B is a detail view of the section view of FIG. 5A
taken through section lines 5B-5B in FIG. 5A.
[0033] FIG. 6 is an exploded perspective view of the machine of
FIG. 4A.
[0034] FIG. 7A is an exploded view of components of a blending
assembly.
[0035] FIG. 7B is another exploded view of the components of FIG.
7A.
[0036] FIG. 7C is an exploded front view of components of a
blending assembly according to the present disclosure.
[0037] FIG. 8 is a central side section view of another machine for
processing a chilled food product.
[0038] FIG. 9 is a flowchart showing an example method of
processing a food product.
[0039] FIG. 10 is a flowchart showing an example method of
processing a food product.
[0040] FIG. 11 is a side section view of another system of the
present disclosure.
[0041] FIG. 11A is a detail view of FIG. 11.
[0042] FIG. 11B is a front section view of the system of FIG.
11.
[0043] FIG. 12A is a perspective exploded view of a rotor-stator
assembly of the system of FIG. 11.
[0044] FIG. 12B is an exploded side sectional view of the
rotor-stator assembly of FIG. 12A.
[0045] FIG. 13A is a side section view of another system of the
present disclosure.
[0046] FIG. 13B is a detail view of the system of FIG. 13A.
[0047] FIG. 14 is a side section view of another system of the
present disclosure.
[0048] FIG. 15A is an isometric view of a rotor assembly of the
present disclosure.
[0049] FIG. 15B is a top view of the rotor assembly of FIG.
15A.
[0050] FIG. 15C is a side central section view of the rotor
assembly of FIG. 15A.
[0051] FIG. 15D is an exploded view of the rotor assembly of FIG.
15A.
[0052] FIG. 16A is a perspective view of another rotor assembly of
the present disclosure.
[0053] FIG. 16B is a top view of the rotor assembly of FIG.
16A.
[0054] FIG. 16C is a side view of the rotor assembly of FIG.
16A.
[0055] FIG. 16D is an exploded perspective view of the rotor
assembly of FIG. 16A.
[0056] While the embodiments described herein are susceptible to
various modifications and alternative forms, specific embodiments
have been shown by way of example in the drawings and will be
described in detail herein. However, the exemplary embodiments
described herein are not intended to be limited to the particular
forms disclosed. Rather, the instant disclosure covers all
modifications, equivalents, and alternatives falling within the
scope of the appended claims.
DETAILED DESCRIPTION
[0057] The present disclosure generally relates to methods and
apparatuses used to process chilled products such as smoothies,
slushes, and other frozen or semi-frozen beverages. Embodiments of
the present disclosure may beneficially reduce the size of ice
crystals in a chilled product by blending or pulverizing the
product continuously, periodically, or in stages as ice crystals
form in the product and/or when the product is requested, served,
or dispensed from a storage container. Thus, frozen beverages
produced by the present systems and methods may be dispensed from a
processing machine with a smoother consistency than beverages
conventionally produced by these machines. In addition, when these
methods are applied to a slush/granita machine, the system may
retain other beneficial properties, such as being simple to
operate, relatively inexpensive, and easily cleaned and
maintained.
[0058] In one embodiment of a processing system 100, shown in
schematic view in FIG. 1, ingredients may be held in a storage
container 102 that is connected to a refrigeration apparatus 108
and a mixing apparatus 104. The storage container 102 may be a
hopper, tank, jar, tub, or other fluid storage device. The
refrigeration apparatus 108 may chill or freeze portions of the
ingredients in the storage container 102, and the mixing apparatus
104 may circulate the frozen and non-frozen portions of the
ingredients to distribute the frozen portions amongst the other
ingredients in the storage container 102. In some embodiments, the
refrigeration apparatus 108 may refrigerate an element within the
storage container 102, such as a bottom surface of the storage
container 102 or a surface extending into the volume of the storage
container (e.g., a refrigerated cylinder).
[0059] The storage container 102 may be connected to a blending
apparatus 106, such as, for example, a blending blade or
rotor/stator assembly, that may come into contact with frozen
portions of the ingredients in (or adjacent to) the storage
container 102. The blending apparatus 106 may be used to break up
and pulverize frozen portions of the ingredients and keep ice
crystals from growing to an undesirable granular size in the
storage container 102 while the frozen ingredients are stored in
the storage container 102. Thus, product served through the
dispenser 110 may have managed consistency based at least in part
on the use of the blending apparatus 106 to smooth frozen portions
in advance of dispensing from the storage container 102.
[0060] Using this system 100, blending may take place while the
product is stored in the storage container 102. In some cases, the
blending apparatus 106 may be connected to the storage container
102, wherein the product may be pumped into the blending apparatus
106 and then returned to the storage container 102. Thus, the
blending apparatus 106 may blend the product while it is in the
storage container 102, or it may blend the product by circulating
the product through an external blending apparatus and back into
the storage container 102. An external blending apparatus may
comprise conduit and pumps to route the product through the
blending apparatus, or product in the storage container 102 may be
drawn into a passage through which the product may be processed by
the blending apparatus 106 while the blending apparatus 106 is
active. The storage container 102 therefore may have portions of
the blending apparatus 106 extending into its internal volume, or
there may be a recess or passage formed in the storage container
102 in which the blending apparatus 106 operates. The main volume
of the storage container 102 may be referred to as a first area of
the storage container, and the passage, recess, or vicinity of the
blending apparatus 106 may be referred to as a second, separate
area of the storage container in fluid communication with the first
area. Thus, the product may be flowed from the first area to the
second area of the storage container to be sheared or blended by
the shearing apparatus. In some embodiments, a passage from the
storage container 102 may lead to a shearing or blending chamber in
which the blending apparatus 106 is located.
[0061] The mixing apparatus 104 may be used to mix the ingredients
in the storage container 102. Due to the mixing apparatus, the
ingredients in the storage container 102 may flow throughout the
storage container 102 and/or recesses/passages that are in fluid
communication with the blending apparatus 106. In one example, the
mixing apparatus 104 may be a vane or auger in the storage
container 102 that is configured to induce flow of the ingredients
in the storage container 102. The mixing apparatus 104 may
beneficially also help prevent ice buildup on a refrigerated
surface in the storage container 102 by scraping the refrigerated
surface as it moves in the storage container 102 or by inducing a
sufficient rate of flow to prevent ice from undesirably
accumulating on the refrigerated surface. In some embodiments, the
entire storage container 102 may be cooled or refrigerated. The
mixing apparatus 104 may therefore be configured to scrape ice or
otherwise circulate or cause flow of ice away from any other ice
formation points in the storage container 102.
[0062] In some arrangements, the blending apparatus 106 may be
operated continuously to keep ice crystals from growing to an
undesirable size in the storage container 102. The blending
apparatus 106 may also be activated periodically or intermittently
to keep the stored product at a predetermined consistency. The
blend timing, speed, and other settings of the blending apparatus
106 may be controlled based on the desired output consistency of
the processing system 100 and the properties of the ingredients
(e.g., their thickness, wetness, and solidity), properties of the
refrigeration system (e.g., its temperature settings and
efficiency), properties of the mixing apparatus (e.g., its size and
mixing efficiency), and properties of the storage container (e.g.,
its size and internal temperature). The blending apparatus 106 may
operate on a schedule or may operate based on temperature, the
granular size of frozen portions of the ingredients in the storage
container 102, the amount of product dispensed over time, the
ingredients used in the storage container 102, or other properties
of the system 100.
[0063] FIG. 2 shows a schematic view of another system 200
according to the present disclosure. As with system 100, this
system 200 includes a storage container 202, mixing apparatus 204,
blending apparatus 206, refrigeration 208, and dispenser 210. In
this embodiment, however, the blending apparatus 206 is configured
to process the product just prior to its delivery to the dispenser
210. In other words, the blending apparatus 206 blends the stored
product primarily "on demand" or in response to a request for the
product (e.g., in response to operation of the dispenser 210 or
another external signaling feature). For example, the dispenser 210
may engage a switch that turns on the blending apparatus 206 when
it is time to dispense the product. The product may then move
through the blending apparatus 206 before being dispensed through
the dispenser 210. The blending apparatus 206 of this embodiment
may therefore be operated substantially only at the time finished
product needs to be dispensed. In some cases, the blending
apparatus 206 may also be briefly operated for maintenance or
sanitation reasons, such as by running the blending apparatus 206
to periodically circulate stationary product inside the blending
apparatus 206 back into the storage container 202 in order to
maintain the consistency of the product throughout the storage
container 202 and blending apparatus 206.
[0064] This system 200 may consistently provide the product at a
desired consistency at the point of dispensing through the
dispenser 210 since ice in the product may be blended to a precise
final consistency at the time it will be served. Thus, the product
should not be able to accumulate larger ice crystals between the
time of shearing and the time of dispensing. Also, the system 200
may more reliably provide an optimal consistency of the product
because only the product being dispensed needs to be at that
consistency while the remaining product in the storage container
202 may have a different consistency. Generally, it is easier to
keep a small amount of the product at a desired consistency than to
keep the entire store of the product at that consistency, so this
system 200 keeps the small amount of product that moves through the
blending apparatus 206 at a desired consistency rather than the
rest of the product in the storage container 202. The rest of the
product in the storage container 202 may also still be circulated
to prevent formation of large frozen crystals, but the size of
those frozen portions does not need to be closely managed since the
final consistency will be reached after shearing in the blending
apparatus 206.
[0065] The settings of the blending apparatus 206 may be controlled
to ensure that the frozen portions of the product (e.g., ice
crystals suspended in the product) that are provided through the
dispenser 210 have a consistent size regardless of the size of the
frozen portions entering the blending apparatus 206 from the
storage container 202. For example, the consistency of the product
in the storage container may be measured at the time a dispensing
signal is received, and the blending apparatus 206 may have its
blending speed and/or duration controlled based on the amount of
post-processing needed to reach a preferable, high-quality
consistency when the product exits the dispenser 210. More or less
speed or time may be necessary based on the thickness and grain
size in the product of the storage container 202.
[0066] In some embodiments, the consistency of the product in the
storage container 202 may be estimated based on the time that the
product has been at a particular temperature in the storage
container 202. For example, in some cases the granular size of the
frozen portions in the storage container 202 may be estimated based
on the length of time the product has been at a certain
temperature, so the blending apparatus 206 may be controlled to
blend at a speed that relates to the time that the product has been
in the storage container 202 at that temperature in order to smooth
frozen portions having that estimated size. In some embodiments,
the consistency of the product may be measured as it is processed
by the blending apparatus, such as while it is moving from the
storage container 202 to the blending apparatus 206. The blending
apparatus 206 may then be controlled based on this measured
consistency so that product with larger chunks of frozen portions
is more refined by the blending apparatus 206 than product with
smaller chunks as it passes through the blending apparatus 206.
[0067] FIG. 3 shows a schematic view of another embodiment of a
system 300 for processing chilled product. As in the embodiments of
FIGS. 1-2, the system 300 may comprise a storage container 302
containing a mixing apparatus 304 and having a connection to a
refrigeration apparatus 308. However, in this system 300, product
in the storage container 302 may be transferable to a separate
shearing container 303 having a blending apparatus 306. Product is
then dispensable through a dispenser 310 upon exiting the shearing
container 303. Thus, product may be mixed and circulated in the
storage container 302 to prevent formation of overly large frozen
portions, but a discrete amount of the product may be blended or
sheared in a separate shearing container 303 that is placed in
series between the storage container 302 and the dispenser 310 to
reach an optimal dispensable consistency.
[0068] In this system 300, ice crystals may form in the storage
container 302 as a result of the refrigeration apparatus 308 and as
the mixing apparatus 304 circulates the product in the storage
container 302. The shearing container 303 generally does not hold a
reserve of the product, but instead a portion of the product may be
delivered or transferred from the storage container 302 to the
shearing container 303 when a request for the finished product is
received (e.g., when the dispenser 310 is operated or another
control signal is sent to the system 300). The portion of the
product is then blended by the blending apparatus 306 to the
desired consistency and is accessible at the dispenser 310.
[0069] This system 300 allows the product to be evenly blended in
discrete batches, so the entire batch has a high likelihood of
having even consistency. Additionally, the implementation of the
shearing container 303 may allow the system 300 to facilitate
additional add-in ingredients to an individual batch as needed. The
additional ingredients may be added to the shearing container 303
without being distributed into product held by the storage
container 302. Furthermore, cleaning and maintenance of the
shearing container 303 may be simple, since the shearing container
303 may have a volume that is smaller and/or easier to access than
the storage container 302. After a custom batch of product is
prepared in the shearing container 303 and dispensed, the shearing
container 303 may then be cleaned before another batch is prepared.
In some embodiments, the shearing container 303 may be sized to
hold a small number of portions or servings of the product, while
the storage container 302 may be sized to hold a plurality of
portions or servings that could be held by the shearing container
303.
[0070] The refrigeration apparatus 308 may provide temperature
control to the storage container 302 and may also provide
temperature control of the shearing container 303. In some
arrangements, the refrigeration apparatus 308 may only provide
cooling to the storage container 302. The temperature of the
product during and after shearing may be controlled more carefully
by providing cooling to the shearing container 303, particularly
for product that needs to be blended for an extended time and
therefore potentially has a significant rise in temperature in the
shearing container 303.
[0071] The schematic views of FIGS. 1-3 are intended to represent
examples of the general concepts of the systems 100, 200, 300 they
represent, and are therefore not intended to restrict the
disclosure to the comparative sizes or spatial positions of
respective elements of the systems 100, 200, 300. Instead, these
systems 100, 200, 300 represent exemplary systems and elements that
may be used to implement embodiments of the present disclosure.
[0072] FIGS. 4A-6 show views of an example embodiment of a
processing system of the present disclosure. These views show an
exemplary implementation of the system 200 of FIG. 2 when applied
to a specific granita/slush machine 400. The machine 400 comprises
a base 402, a hopper 404, a refrigeration assembly 406, a dispenser
apparatus 408, and a blending assembly 410. An auger 412 is
positioned to rotate around a refrigerated cylinder 414 within the
hopper 404. The auger 412 and/or cylinder 414 may be configured to
axially rotate within the hopper 404 to circulate fluids in the
hopper 404 and to keep frozen portions of product in the hopper 404
from accumulating on the refrigerated cylinder 414 over time. In
some embodiments, the auger 412 may have a helical shape configured
to circulate product in the hopper 404 toward the front of the
hopper 404 where it can be dispensed through the blending assembly
410 and dispenser apparatus 408.
[0073] The refrigeration assembly 406 is shown in FIG. 5A
referencing the auger motor 454. Additional refrigeration assembly
406 components such as, for example, a condenser, an evaporator,
coils, and/or a pump, are not shown. Thus, the refrigeration
assembly 406 is representative of a generic refrigeration assembly
that would be implemented to chill or freeze product in the hopper
404 without reference to specific features or components of the
refrigeration assembly 406.
[0074] The hopper 404 may comprise an inner surface 416 defining an
inner volume 418 for storage of product in the machine 400. The top
of the hopper 404 may be covered or sealed to keep the internal
product clean. The hopper 404 may also comprise a lower opening 420
through which product may enter the blending assembly 410. See
FIGS. 5A-5B. In the embodiment shown, the lower opening 420 is
formed in a bottom surface of the hopper 404 and product flows
downward from the hopper 404 into the blending assembly 410. In
other embodiments, the lower opening 420 may be formed in a
sidewall of the hopper 404 and product may flow laterally or
diagonally from the hopper 404 into the blending assembly 410. For
example, in some configurations the blending assembly 410 may have
components configured to rotate primarily in a vertical plane and
product may enter the blending assembly 410 through a side opening
in the blending assembly 410.
[0075] The inner surface 416 of the hopper 404 may have a shape
configured to maximize the efficiency of the auger 412 as it
circulates product in the inner volume 418. For example, as shown
in FIGS. 4A-4B, the hopper 404 may comprise a contoured portion 422
where the auger 412 is positioned so that the inner surface 416 is
close to the auger 412. Thus, the auger 412 may scrape frozen
portions of product from the inner surface 416 of the hopper 404 in
addition to scraping frozen portions from the refrigerated cylinder
414.
[0076] The front of the machine 400 comprises the dispenser
apparatus 408 and the blending assembly 410. FIGS. 5A-7C show
details of the blending assembly 410. The blending assembly 410 may
include a rotor 424, a stator 426, a base housing 428, and a drive
motor 430. The blending assembly 410 may comprise an entry opening
440. The entry opening 440 allows product in the hopper 404 to move
into the blending assembly 410. In this embodiment, the rotor 424
is configured to rotate in a horizontal plane, as indicated in FIG.
5B. In other arrangements, the rotor 424 may be rotated in a
vertical plane and the stator 426 may therefore also be rotated to
receive product from the hopper 404 from a lateral direction.
[0077] The rotor 424 and stator 426 may be concentrically aligned
and may each comprise a plurality of blades 432, 434. The blades
432 of the rotor 424 may extend upward from a base surface 436 of
the rotor 424 (see FIG. 7A), and the blades 434 of the stator 426
may extend downward from a base surface 438 of the stator 426 (see
FIG. 7B). The blades 432, 434 of the rotor 424 and stator 426 may
be arranged to radially fit between each other (see FIG. 5B) so
that the blades 432 of the rotor 424 extend proximate to the base
surface 438 of the stator 426, and the blades 434 of the stator 426
extend proximate to the base surface 436 of the rotor 424. When the
rotor 424 is rotated at a high speed, the blades 432 spin between
the blades 434 of the stator 426 and pulverize any material between
the rotor 424 and stator 426.
[0078] The product being processed by the rotor 424 and stator 426
is contained by the stator 426 and the base housing 428. It may
enter the blending assembly 410 through an entry opening 440 in the
stator 426 and exit the blending assembly 410 through an exit
opening 442 (see FIG. 5B) formed by a lower exit opening 444 in the
base housing 428 and an upper exit opening 446 in the stator 426.
The entry opening 440 may be sized to receive flow from the hopper
404 at a rate sufficient to provide consistent flow through the
exit opening 446 of the blending assembly 410 and an exit opening
448 of the hopper 404. See FIGS. 5B and 6.
[0079] Because product is blended by the blending assembly 410
external to the inner volume 418 of the hopper 404, the blending
assembly 410 may be referred to as being an external blending
assembly 410. Because product must pass through the blending
assembly 410 to be dispensed through the dispenser apparatus 408,
the blending assembly 410 may be referred to as being positioned in
series (or "serially") between the hopper 404 and the dispenser
apparatus 408. Additionally, because the base housing 428 forms a
lower surface that extends downward from the base of the hopper 404
(as shown in FIGS. 5A-5B), the blending assembly 410 may be
referred to as being fitted in a recess in the hopper 404.
[0080] The stator 426 and base housing 428 of the blending assembly
410 may comprise contoured upper surfaces 450, 452. The contours of
the upper surfaces 450, 452 may be shaped to accommodate and follow
the outer path of the auger 412 as it rotates within the hopper
404. The contours may thereby limit the formation or accumulation
of ice or other stationary product on the upper surfaces 450, 452
since their proximity to the auger 412 may scrape off ice or other
stationary product.
[0081] The motor 430 may drive the rotation of the rotor 424. The
motor 430 shown in these figures is a direct-drive motor with a
driveshaft directly extending into contact with the rotor 424, but
in other embodiments the motor 430 may be repositioned elsewhere in
the machine 400 and the rotor 424 may be driven by a gearing, belt
drive, or another indirect drive system. The motor 430 of these
figures therefore indicates one possibility of a motor 430 that may
be used with the machine 400 to drive the blending assembly 410. In
other arrangements, the auger motor 454 (see FIG. 5A) or another
motor in the machine 400 may drive the rotor 424.
[0082] The rotor 424 and stator 426 are also provided in these
figures as a representation of an exemplary embodiment of a
blending apparatus, and are not intended to be limiting of the
scope of the various ways that product may be blended as it is
dispensed from a hopper 404. For example, those having ordinary
skill in the art and having the benefit of the present disclosure
may understand that a blending blade (e.g., blade 508 of FIG. 8) or
other blending device may be used to blend, crush, thrash, and
pulverize product. The blending blade or device may be positioned
to rotate in the base housing 428 or may extend at least partially
into the inner volume 418 of the hopper 404.
[0083] The dispenser apparatus 408 may be a dispenser apparatus 408
used in a conventional drink dispensing machine. Movement of the
dispenser apparatus 408 downward in front of the hopper 404 may
move the exit opening 448 of the dispenser apparatus 408 into
alignment with the exit opening 442 of the blending assembly 410
(see FIG. 5B) and allow product blended by the blending assembly
410 to exit through a spout 456. The movement of the dispenser
apparatus 408 may also trigger a switch or otherwise generate a
signal that engages the blending assembly 410. In this manner, the
blending assembly 410 may begin blending the product to be
dispensed as the dispenser apparatus 408 moves downward. By the
time the exit openings 442, 448 are aligned, the product in the
blending assembly 410 may have the preferred consistency for
dispensing to a customer through the spout 456. Then, if the
openings 442, 448 remain aligned, an additional supply of product
flowing into the blending assembly 410 may be blended immediately
before flowing out through the spout 456.
[0084] FIG. 8 shows another alternative embodiment of a chilled
product processing machine 500 of the present disclosure. This
processing machine 500 contains separate storage and shearing
containers and is an example implementation of the system 300 of
FIG. 3. This machine 500 may comprise a hopper 404, dispenser
apparatus 408, auger 412, and cylinder 414 as described in
connection with machine 400, and may also comprise a blending
chamber 502 connected to the hopper 404. The blending chamber 502
may receive product from the hopper 404 through a fill opening 504
in the lower portion of the hopper 404. The fill opening 504 may be
opened and closed (or covered and uncovered) in order to dispense
product into the blending chamber 502. In some embodiments, the
fill opening 504 may have its open-closed state controlled so that
a predetermined or measured amount of product is dispensed into the
blending chamber 502. For example, the fill opening 504 may be
opened for a predetermined length of time based on the amount of
product in the hopper 404. The fill opening 504 may also be opened
until a predetermined mass or volume of product is measured in the
blending chamber 502, at which point the fill opening 504 may be
closed or covered. Having a separate blending chamber 502 may allow
the user of the machine 500 to blend individual portions, servings,
or batches of product with a consistently high level of quality
since each batch is processed independently and may be processed
until the desired consistency of product is reached.
[0085] The blending chamber 502 may be integrated into a base
housing 506 of the machine 500 or may be a container detachable
from the base housing 506. The blending chamber 502 may contain a
blending blade 508 driven by a blending motor 510. The blending
chamber 502 may therefore contain product as it is blended by the
blending blade 508. After the product is blended to a desired
consistency, the product may exit the blending chamber 502 through
an opening 512 positioned in communication with an opening 514 in
the spout of the dispenser apparatus 408. In some cases, the
blending chamber 502 may be moved or removed from the machine 500
to dispense or pour out product that has been processed by the
blending blade 508. For example, the blending chamber 502 may be
pivotable or removable away from the machine 500 to pour out
refined product. In some embodiments, the blending blade 508 may
extend into the blending chamber 502 from a direction other than
the bottom of the blending chamber 502, or the blending blade 508
may be replaced with another pulverizing apparatus, such as a
rotor-stator assembly, a grinder, slicing blade, milling device,
food processor blade, or an equivalent device.
[0086] In some arrangements, the blending chamber 502 may also
comprise a secondary fill opening configured to receive ingredients
into the blending chamber 502. The secondary fill opening may be
covered by a door or other blocking element to prevent product from
being expelled from the blending chamber 502 while the blending
blade 508 is in operation. Due to the secondary fill opening,
additional ingredients may be added to the product in the blending
chamber 502 without the additional ingredients entering the hopper
404. This may be advantageous when fresh or frozen ingredients need
to be added to the product.
[0087] Another embodiment of the present disclosure is a method 600
shown in the flowchart of FIG. 9. The method 600 may comprise
providing a product in a storage container, as shown in block 602.
The product may be partially frozen, either by being frozen in the
storage container or by being added to the storage container in a
partially frozen state. The product may thereby comprise a frozen
portion and a non-frozen portion in the storage container. The
frozen portion may comprise ice crystals and/or other ingredients
frozen in ice, and the non-frozen portion may comprise fluid and
solid ingredients mixed with the frozen portion. For example, the
frozen portion may comprise ice pellets or ice crystal
grains/particles formed in the product, and the non-frozen portion
may comprise ingredients such as water, milk, banana pieces,
strawberry puree, and/or syrup. The frozen portion of the product
may have a granular size. A "granular size" may refer to a size
dimension of the granules of ice crystals or other frozen
ingredients in the product, such as the average diameter, volume,
width, or length of individual "grains" of these portions of the
product. Granular size may alternatively refer to the weight of a
grain of the frozen ingredients.
[0088] The frozen portion of the product may be mixed with the
non-frozen portion of the product within the storage container, as
shown in block 604. In some embodiments, a mixing device such as a
vane, auger, or propeller mixes the product in the storage
container. The mixing may generally evenly disperse and distribute
the frozen portion among the non-frozen portion. Thus, the product
may be a slush of frozen and non-frozen components that are
intermixed.
[0089] The frozen portion and non-frozen portion of the product may
flow into contact with a shearing apparatus, as shown in block 606.
The product may flow due to movement of a mixing device or due to
gravity acting on the product. For example, an auger or other
mixing device may rotate and thereby induce flow through the
storage container, such as by circulating the product to the
shearing apparatus. In another example, an opening in the storage
container or shearing apparatus may be opened and permit flow into
contact with the shearing apparatus due to the product being
pressured into or toward a drain or dispenser opening by gravity or
fluid pressure.
[0090] The shearing apparatus may then be used to shear at least
the frozen portion of the product that comes into contact with the
shearing apparatus, and this shearing may reduce the granular size
of the frozen portion of the product, as indicated by block 608. If
the frozen portion comprises ice crystals, for example, the
shearing apparatus may pulverize the ice crystals and thereby
reduce their size. This may smooth the overall consistency of the
product, and a preferred granular size of frozen portions of the
product may thereby be produced. "Shearing" a product may refer to
processing a product by blending, breaking up, intermixing,
pulverizing, crushing, smashing, rending, smearing, disintegrating,
fragmenting, fracturing, applying a shearing force to, and/or
disbanding the product such that solid granules in the product are
reduced in size and distributed amongst other ingredients in the
product. A "shearing apparatus" may comprise an apparatus
configured for shearing a product. In some embodiments, portions of
the product other than frozen portions may be sheared by the
shearing apparatus. In some cases, non-frozen solid ingredients
(e.g., seeds, chocolate chips, or berries), semi-solid ingredients
(e.g., peanut butter), or viscous liquid ingredients (e.g., syrups)
may be sheared, pulverized, or blended by the shearing apparatus to
reduce the size of chunks of these ingredients and distribute them
more evenly throughout the finished product.
[0091] FIG. 10 is a flowchart indicating another example embodiment
of a method of processing a food product stored in a storage
container. The method 700 may comprise providing a storage
container in fluid communication with a blending apparatus in block
702, wherein a food product stored by the storage container is
dispensable from the storage container by flowing into the blending
apparatus and then out of the blending apparatus through a
dispenser.
[0092] In block 704, the method 700 may comprise receiving a
request for the food product. The request for a food product may
include detecting operation of the dispenser or an input device
(e.g., a control button) by a user.
[0093] Block 706 sets forth enabling flow of the food product into
the blending apparatus. The flow may be enabled by operating a
mixing apparatus in the storage container or by inducing flow of
the food product by gravity or fluid pressure. For example, an
opening the storage container may be opened or uncovered and the
food product may be drawn into the blending apparatus due to
gravity and/or fluid pressure drawing the food product through the
opening.
[0094] In block 708, the blending apparatus may be engaged, thereby
shearing the food product in the blending apparatus. The blending
apparatus may be engaged as a result of operation the dispenser.
For example, the movement of the dispenser may activate a switch or
send a signal to a controller of the blending apparatus that turns
on the blending apparatus.
[0095] Block 710 includes enabling flow of the food product through
the dispenser. This may entail allowing the dispenser to open
sufficiently to allow the food product to escape through the
dispenser, such as by aligning an exit opening in the blending
apparatus with an opening or spout in the dispenser. In some
embodiments, the food product may flow through the blending
apparatus and directly through the dispenser, and in some cases the
food product may be contained by the blending apparatus at least
temporarily before being permitted to flow through the
dispenser.
[0096] FIGS. 11-11A are side section views of an additional
embodiment of a system 800 for post-processing a chilled product.
The system 800 may comprise a hopper 802, a blending apparatus 804,
and a dispensing assembly 806. In some arrangements, various other
components may be included as well, such as, for example, a unit
for refrigeration (e.g., refrigeration 208) and a mixing apparatus
(e.g., 204).
[0097] System 800 has a dispensing assembly 806 that is controlled
by pushing or pulling a sealed rod 808 that opens or closes a
dispensing passage 810 through the dispensing assembly 806. The
rate of flow of product out of the dispensing assembly 806 may be
controlled by the amount of displacement of the rod 808, since the
displacement of the rod 808 directly controls the size of the
opening exiting the rotor-stator assembly 814 to the passage 810.
In some embodiments, the rod 808 may be displaced by a lever or
handle system 811 connected to the rod 808, wherein the user may
operate the lever or handle system to move the rod 808.
[0098] Some configurations of the system 800 have a dispensing
assembly 806 that may electronically activate the blending
apparatus 804. Thus, operating the dispensing assembly 806, such as
by pulling a handle system 811, may activate the blending apparatus
804, such as by turning on a motor 812 in the blending apparatus
804 and causing a rotor 816 of the blending apparatus 804 to
rotate.
[0099] The blending apparatus 804 may comprise a motor 812 and a
rotor-stator assembly 814. The motor 812 may be configured to drive
a rotor 816 in the rotor-stator assembly 814 via a driveshaft 818
connected to the rotor 816. See FIG. 11A. In the embodiment of
FIGS. 11-11A, the motor 812 is shown directly driving the rotor
816, but in other embodiments the motor 812 may be positioned
elsewhere within the system 800 (e.g., elsewhere underneath the
hopper 802) and may be linked to the rotor 816 by a gearbox or
other transmission device in the system 800. Thus, the motor 812 of
system 800 is shown as an example configuration of many alternative
configurations.
[0100] FIG. 11A is a detail view of the cross-sectional view of
FIG. 11. This view illustrates the relative positioning of the
rotor 816 and a stator 820 in the rotor-stator assembly 814. The
rotor 816 is positioned beneath and at least partially enclosed by
the stator 820. A drip pan 822 may be positioned beneath the rotor
816 and stator 820, and the drip pan 822 and stator 820 may
collectively comprise a housing for the rotor 816. The drip pan 822
may comprise a driveshaft opening 824 through driveshaft bearings
826 to allow the driveshaft 818 to extend into engagement with the
rotor 816. Driveshaft bearings 826 and seals 828 may hold the
driveshaft 818 in the driveshaft opening 824 and prevent leaks
through the drip pan 822. The stator 820 may comprise an exit
opening 830 that is configured to connect to the dispensing
assembly 806 and provide fluid communication with the passage 810
when the rod 808 exposes the passage 810 to the exit opening
830.
[0101] The rotor-stator assembly 814 may contact the underside of
or extend into the hopper 802, and in some embodiments a seal or
gasket 832 may seal the hopper 802 and the rotor-stator assembly
814. It may be beneficial to have the rotor-stator assembly 814
have an upper contour that follows the lower contour of the hopper
802 to facilitate continuous flow in the hopper 802 when product is
mixed therein, to prevent interference with mixing apparatus in the
hopper 802, and/or to reduce leaking between the hopper 802 and the
rotor-stator assembly 814. FIG. 11B is a front section view of the
system 800 of FIG. 11 taken through section lines 11B-11B in FIG.
11. In some arrangements, the rotor-stator assembly 814 may follow
the bottom rounded curvature of the hopper 802.
[0102] The rotor 816 may be removable from the driveshaft 818. In
some cases, the rotor 816 may be threaded to the driveshaft 818 and
held thereon by a fastener 834. See also FIGS. 12A-12B. The
fastener 834 may also be threaded onto the driveshaft 818. The
fastener 834 may comprise a plurality of vanes 836 or grip features
to facilitate easier tightening of the fastener 834 to the
driveshaft 818. See FIG. 12A. The vanes 836 may mix and stir
product that enters the stator 820 from the hopper 802, thereby
redirecting the product from the center of the rotor 816 in an
outward radial direction to a position between the rotor 816 and
stator 820.
[0103] The function of the rotor-stator assembly 814 is described
with reference to FIGS. 11A-12B. The rotor 816 has a horizontal
surface portion 838, an angled surface portion 840, and a vertical
surface portion 842, each of which are textured with
radially-directed ridges 843. As product enters the rotor-stator
assembly 814, the product first contacts the horizontal surface
portion 838 after passing through an upper opening 844 of the
stator 820, then flows outward due to centripetal forces and/or the
movement of the vanes 836 to a position on the horizontal surface
portion 838 that is underneath an angled surface 846 of the stator
820. At this point, the product continues outward to a position
between the angled surface portion 840 of the rotor 816 and the
angled surface 846 of the stator 820. The angled surface 846 of the
stator 820 also comprises a plurality of radially-directed ridges
848. The distance between these angled surfaces 840, 846 at the
peaks of the ridges 843, 848 may be small, typically within a range
having an upper bound of about 0.050 inches and a lower bound less
than about 0.005 inches, while the distance between the angled
surface 846 and the horizontal surface portion 838 is typically a
greater distance that tapers down to the distance between the
angled surfaces 840, 846. In one preferable embodiment, the
distance between the angled surfaces 840, 846 is about 0.020
inches. Thus, as the product enters the positions between the
angled surfaces 840, 846 any ice or granules of solid material in
the product is ground up and sheared between the ridges 843, 848 as
it moves outward. Gravity, centripetal forces, and forces applied
from pressure of product that is at the horizontal surface portion
838 cause the product between the angled surfaces 840, 846 to
progress outward and downward until it is positioned adjacent to
the vertical surface portion 842 of the rotor 816 and eventually
swept out through the exit opening 830 of the stator 820 and
through the dispensing assembly 806. The high speed rotation of the
rotor 816 (typically between about 4,000 and about 10,000
revolutions per minute) pulverizes and smooths out the product
throughout this process so that chunks or other undesirably large
crystals in the product are reduced and processed just before being
dispensed.
[0104] As shown in FIG. 12B, each of the individual ridges 843, 846
may have an asymmetric cross-sectional profile similar to a wave
shape or a swept, offset triangular shape. See also FIGS. 15A-15D.
Because the rotor 816 is typically only turned in one direction,
the leading side of a ridge 843, 846 may have a steeper slope than
its trailing side. This spaces apart the ridges and makes it easier
to clean the spaces between ridges.
[0105] FIGS. 13A-13B show an alternative embodiment of a system 900
for post-processing a chilled product. This system 900 has the
hopper 802 and blending apparatus 804 of the system 800 of FIGS.
11-12B. The dispensing assembly 902, however, has a
horizontally-oriented rod 904 used as a stopper for the passage 906
exiting the dispensing assembly 902. The rod 904 may be withdrawn
from the dispensing assembly 902 to open the passage 906 and allow
product to exit the system 900 through the exit opening 830 of the
stator 820. Thus, these figures show that the dispensing assembly
902 may be oriented with a passage 906 and rod 904 that are
oriented in a different direction compared to the other systems
200, 800 disclosed herein. The passage 906 in the dispensing
assembly 902 may open directly downward in this embodiment as
compared to the passage 810 of FIG. 11 that opens at a downward
angle. A horizontally-oriented rod 904 may allow the minimum amount
of volume between the exit opening 830 of the stator 820 and the
opening of the exit passage 906. Minimizing this volume reduces the
amount of product that must be pushed back through the rotor 816
and stator 820 when the rod 904 closes. In some cases, if the
product does not get pushed back through the rotor 816 and stator
820 it may be compressed in that space and may form an ice dam that
can block subsequent product flow.
[0106] FIG. 14 shows another alternative embodiment of a system
1000 for post-processing a chilled product. This system 1000 has a
blending apparatus 804 of the systems 800, 900 described above and
an alternative hopper 1002 shape and dispenser 1004. The hopper
1002 has a sloped front surface that reduces the volume of the
system 1000 and space required for the system to be stored. The
sloped surface 1006 also may permit easier viewing of the contents
of the hopper 1002 from the front of the system 1000 and may be
beneficial for aesthetic reasons. The dispenser 1004 may contain a
rod that is vertically movable through an internal passage of the
dispenser 1004. As in other embodiments disclosed herein, the rod
may act as a valve controlling flow out of the system 1000 based on
the position of the rod in the passage. The rod may be moved by
hand or may be connected to a handle or lever system.
[0107] FIGS. 15A through 15D illustrate an alternative embodiment
of a rotor 1100 for use in systems disclosed herein. One difference
between the rotor 1100 of these figures and rotor 816 is that rotor
1100 is a single, integral piece connected to a driveshaft 1102, as
compared with rotor 816 which is connected to the driveshaft 818 in
conjunction with fastener 834. The rotor 816 and/or fastener 834 is
threaded to driveshaft 818 to remain engaged with the driveshaft
818, but rotor 1100 may be engaged with the driveshaft 1102 by a
pressure fit or friction fit using an o-ring 1104 or other gasket
that is positioned around the driveshaft 1102 and can be received
by a retaining seat 1106 within an internal cavity 1108 of the
rotor 1100. See FIG. 15C. This design may facilitate easier
cleaning of the rotor 1100 and may reduce the part count of the
system in which it is implemented, thereby potentially reducing
production and maintenance costs.
[0108] The driveshaft 1102 may also comprise a non-cylindrical
engagement member 1110 configured to fit within and mate with a
correspondingly-shaped engagement surface 1112 in the rotor 1100.
In this embodiment, the engagement member 1110 has a rounded
rectangular shape (when viewed from above or in horizontal
cross-section) that fits within and mates with the corresponding
rounded rectangular engagement surface 1112. Thus, the driveshaft
1102 may have a non-cylindrical shape that engages with the rotor
1100 to rotate the rotor 1100 without using threads. Torque may be
transferred by the engagement member 1110 to the rotor 1100 via
contact with the engagement surface 1112. The engagement member
1110 and engagement surface 1112 in other embodiments may comprise
other shapes, such as, for example, a triangular, gear-shaped, or
star-shaped cross section.
[0109] The surface of the rotor 1100 may comprise a horizontal
portion 1114, an angled portion 1116, and a vertical portion 1118
that may respectively serve the same functions as the horizontal
surface portion 838, angled surface portion 840, and vertical
surface portion 842 of rotor 816.
[0110] FIGS. 16A-16D illustrate yet another embodiment of a rotor
assembly 1200 for use in systems disclosed herein. FIG. 16A shows a
perspective view of the rotor assembly 1200, FIG. 16B is a top
view, FIG. 16C is a side view, and FIG. 16D is an exploded
perspective view. The rotor assembly 1200 may comprise a rotor 1202
and a driveshaft 1204. The rotor 1202 may include a top surface
1206 having peripheral horizontal, angled, and vertical portions
similar to the surface of rotor 1100. The driveshaft 1204 may
comprise an elongated shaft portion 1210 configured to extend
through a central aperture 1212 in the rotor 1202. The central
aperture 1212 may have a hexagonal shape in order to engage a
hexagonally shaped shaft portion 1210 of the driveshaft 1204. Thus,
rotation of the shaft portion 1210 may cause rotation of the rotor
1202. In other embodiments, a different aperture profile may be
used, such as a square, triangular, or octagonal shape, provided
that the surfaces of the aperture 1212 and shaft portion 1210 can
engage during axial rotation of the shaft portion 1210.
[0111] The central area of the top surface 1206 may include a
plurality of compliant attachment members 1208. The compliant
attachment members 1208 may extend upward from the top surface 1206
of the rotor 1202 and may extend inward relative to the shaft
portion 1210 of the driveshaft 1204 to engage a groove 1214 (see
FIG. 16D) in the upper end of the shaft portion 1210. The groove
1214 may be positioned spaced from the top surface 1206 of the
rotor 1202. The compliant attachment members 1208 may prevent
relative sliding motion between the rotor 1202 and the driveshaft
1204 so that the rotor 1202 does not slide up and off of the shaft
portion 1210 while in use. Another advantage of the rotor assembly
1200 is that there are no blind holes, so it may be easier and
faster to clean than embodiments that have blind holes.
[0112] The upward extending portion of the compliant attachment
members 1208 may be referred to as a post 1216, and the
inward-projecting portion of the compliant members 1208 may be
referred to as a compliant arm 1218 that extends from the post
1216. In some embodiments, the compliant arm 1218 may extend from
the post 1216 without any intervening portion, but in the
embodiments shown in FIGS. 16A-16D, the compliant arm 1218 extends
from a vane portion 1220 that is connected to the post 1216. The
vane portion 1220 may extend tangentially or circumferentially away
from the post 1216 at an inward angle A relative to the tangential
direction, as shown in FIG. 16B. The vane portion 1220 may have
broad outer surfaces (i.e., surfaces facing away from the groove
1214) that deflect and push product peripherally while rotating. In
the embodiment of FIGS. 16A-16D, the vane portions 1220 have a
generally rectangular shape that has a compact yet broad surface
area (see FIGS. 16C-16D).
[0113] The vane portions 1220 may be spaced above the top surface
1206 of the rotor 1202, as shown in FIG. 16C, to allow product that
has reached the top surface 1206 to flow apart from the vane
portions 1220. The spacing may also make cleaning the top surface
1206 faster and easier and may make the compliant attachment
members 1208 as a whole more flexible relative to the rest of the
rotor 1202.
[0114] Torque to drive the rotor 1202 may be transferred at the
aperture 1212 so that the compliant attachment members 1208 receive
little or no torque from the driveshaft 1204. The compliant arms
1218 of the system may comprise a flexible material and may be
dimensioned to resiliently flex radially outward to allow the tip
1222 of the shaft portion 1210 to be inserted through the space
between the compliant arms 1218 and then to flex back inward when
the groove portion 1214 reaches the longitudinal position of the
compliant arms 1218. When removing the rotor 1202, the opposite
flexing action may take place.
[0115] In some embodiments, a flex stop portion 1224 may be
integrated as part of a compliant arm 1218 that connects the
compliant arm 1218 to the vane portion 1220 and/or the post 1216.
The flex stop portion 1224 may be a lofted or webbed surface that
increases the thickness of the compliant arm 1218, thereby
increasing the stiffness of the portion of the compliant arm 1218
that is attached to the flex stop portion 1224. In this manner, the
stiffness and flexibility of different portions of the compliant
arm 1218 may differ from each other, which may beneficially allow
the compliant attachment members 1208 to flex where needed to snap
onto the driveshaft 1204 without being flexible enough for
inadvertent disconnection therefrom and to allow the vane portions
1220 to be rigid enough to deflect heavy or thick product that is
positioned above the rotor 1202.
[0116] The present description provides examples, and is not
limiting of the scope, applicability, or configuration set forth in
the claims. Thus, it will be understood that changes may be made in
the function and arrangement of elements discussed without
departing from the spirit and scope of the disclosure, and various
embodiments may omit, substitute, or add other procedures or
components as appropriate. For instance, the methods described may
be performed in an order different from that described, and various
steps may be added, omitted, or combined. Also, features described
with respect to certain embodiments may be combined in other
embodiments.
[0117] Various inventions have been described herein with reference
to certain specific embodiments and examples. However, they will be
recognized by those skilled in the art that many variations are
possible without departing from the scope and spirit of the
inventions disclosed herein, in that those inventions set forth in
the claims below are intended to cover all variations and
modifications of the inventions disclosed without departing from
the spirit of the inventions. The terms "including:" and "having"
come as used in the specification and claims shall have the same
meaning as the term "comprising."
* * * * *