U.S. patent application number 16/459322 was filed with the patent office on 2020-02-20 for rapidly cooling food and drinks.
The applicant listed for this patent is Sigma Phase, Corp.. Invention is credited to Robert Devaney, Matthew Fonte, Nicholas Fonte, John Heymans, Ian McGirty.
Application Number | 20200056835 16/459322 |
Document ID | / |
Family ID | 67809725 |
Filed Date | 2020-02-20 |
View All Diagrams
United States Patent
Application |
20200056835 |
Kind Code |
A1 |
Fonte; Matthew ; et
al. |
February 20, 2020 |
RAPIDLY COOLING FOOD AND DRINKS
Abstract
Systems and methods have demonstrated the capability of rapidly
cooling the contents of pods containing the ingredients for food
and drinks.
Inventors: |
Fonte; Matthew; (Concord,
MA) ; Devaney; Robert; (Auburndale, MA) ;
Heymans; John; (Hampstead, NH) ; Fonte; Nicholas;
(Sudbury, MA) ; McGirty; Ian; (Chelmsford,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sigma Phase, Corp. |
Lexington |
MA |
US |
|
|
Family ID: |
67809725 |
Appl. No.: |
16/459322 |
Filed: |
July 1, 2019 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
16104758 |
Aug 17, 2018 |
10334868 |
|
|
16459322 |
|
|
|
|
62758110 |
Nov 9, 2018 |
|
|
|
62801587 |
Feb 5, 2019 |
|
|
|
62831657 |
Apr 9, 2019 |
|
|
|
62831600 |
Apr 9, 2019 |
|
|
|
62831646 |
Apr 9, 2019 |
|
|
|
62831666 |
Apr 9, 2019 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A23G 9/12 20130101; B65D
85/804 20130101; F25D 25/005 20130101; F25D 2400/28 20130101; A23G
9/52 20130101; A23G 9/106 20130101; B01F 7/18 20130101; B65D
85/8046 20130101; F25D 31/007 20130101; F25D 2331/805 20130101;
A47J 43/07 20130101; B65D 85/78 20130101; A23G 9/28 20130101; A23G
9/22 20130101; B65D 85/8043 20130101; A23G 9/08 20130101; F25D
31/002 20130101 |
International
Class: |
F25D 31/00 20060101
F25D031/00; F25D 25/00 20060101 F25D025/00; A47J 43/07 20060101
A47J043/07; B01F 7/18 20060101 B01F007/18 |
Claims
1. A pod for forming a cold food or drink, the pod comprising: a
body with an axis, a first end, a second end opposite the first
end, and a sidewall extending from the first end to define an
interior cavity of the body open at the second end, the second end
of the body having a radius that is less than an average radius of
the body; a mixing paddle disposed in the interior cavity of the
body; and a base extending across the open end of the body, the
base sealed to the sidewall of the body; wherein the pod contains
pressurized gas and the pod is internally pressurized to at least
20 psi prior to use.
2. The pod of claim 1, wherein the body and the base form a
can.
3. The pod of claim 2, wherein the base includes a protrusion
extending outward relative to adjacent portions of the base.
4. The pod of claim 32, wherein the base comprises a weakened
section extending around the protrusion.
5. The pod of claim 1, further comprising a cap attached to the
body, the cap extending over at least part of the base and
rotatable per relative to the base, the cap defining an opening
extending through the cap.
6. The pod of claim 5, wherein the base includes a protrusion
extending outward relative to adjacent portions of the base, the
protrusion having a stem that extends between a head and a foot,
the stem having a smaller cross-section than the head and the foot,
the base comprising a weakened section extending around the
protrusion.
7. The pod of claim 6, wherein the cap has a ramp adjacent the
opening extending through the cap, the ramp sized and positioned to
lift the protrusion and break the weakened section to separate the
protrusion from the adjacent portions of the base when the cap is
rotated.
8. The pod of claim 5, wherein the cap is rotatable around the axis
of the body.
9. The pod of claim 1, further comprising a plug closing an opening
extending through the base.
10. The pod of claim 9, wherein the plug comprises a slider
disposed between the cap and the base, the slide rotatable relative
to the base.
11. The pod of claim 9, wherein the plug comprises a foil seal and
the cap is positioned to engage and remove the foil seal from the
opening defined extending through the base on rotation of the
cap.
12. (canceled)
13. The pod of claim 31, wherein the at least one blade is a
plurality of blades.
14. The pod of claim 13, wherein each blade has two or more
different angles of inclination relative to a plane perpendicular
to the axis of the body.
15. The pod of claim 14, wherein the mixing paddle comprises a
disc-shaped head that extends to the sidewall of the body.
16. The pod of claim 13, wherein the mixing paddle is made of a
resilient material that resumes an original shape after being
compressed to fit through the open end of the body.
17. The pod of claim 13, wherein the mixing paddle has at least one
blade that has grooves in an outer edge, the grooves sized to
receive a rim of the open end of the body to enable insertion of
the mixing paddle into the interior cavity of the body by rotation
of the mixing paddle with the rim in the grooves.
18. The pod of claim 1, further comprising a vessel containing
pressurized gas disposed in the interior cavity of the body.
19. (canceled)
20. A can containing at least one ingredient to form a cold food or
drink, the can comprising: a metal body with an axis, a closed end,
an open end opposite the closed end, and a sidewall extending from
the closed end to define an interior cavity of the body, the open
end of the body having a radius that is less than an average radius
of the body; a mixing paddle with at least one blade extending
laterally farther from the axis of the body than the radius of the
open end of the body, the mixing paddle disposed in the interior
cavity of the body and rotatable relative to the body; and a base
extending across the open end of the body, the base sealed to the
sidewall of the body; wherein the base includes a protrusion
extending outward relative to adjacent portions of the base, the
protrusion having a stem that extends between a head and a foot,
the stem having a smaller cross-section than the head and the foot,
the base comprising a weakened section extending around the
protrusion.
21. (canceled)
22. The can of claim 20, further comprising a cap attached to the
body, the cap extending over at least part of the base and
rotatable per relative to the base, the cap defining an opening
extending through the cap;
23. The can of claim 22, wherein the cap is rotatable around the
axis of the body.
24. The can of claim 20, wherein the at least one blade has grooves
in an outer edge, the grooves sized to receive a rim of the open
end of the body to enable insertion of the mixing paddle into the
interior cavity of the body by rotation of the scraper with the rim
in the grooves.
25. The can of claim 20, further comprising a vessel containing
pressurized gas disposed in the interior cavity of the body.
26. (canceled)
27. A pod containing at least one ingredient to form a cold food or
drink, the pod comprising: a metal body with a closed end, an open
end opposite the closed end, and a sidewall extending from the
closed end to define an interior cavity of the body; a mixing
paddle disposed in the interior cavity of the body and rotatable
relative to the body; and a base extending across the open end of
the body, the base sealed to the sidewall of the body, the base
including a protrusion with a stem that extends between a head and
a foot, the stem having a smaller cross-section than the head and
the foot, the base comprising a weakened section extending around
the protrusion.
28. The pod of claim 27, further comprising a cap attached to the
body, the cap extending over at least part of the base and
rotatable per relative to the base, the cap defining an opening
extending through the cap;
29. The pod of claim 28, wherein the mixing paddle has at least one
blade that has grooves in an outer edge, the grooves sized to
receive a rim of the open end of the body to enable insertion of
the scraper into the interior cavity of the body by rotation of the
scraper with the rim in the grooves.
30. The pod of claim 27, further comprising a vessel containing
pressurized gas disposed in the interior cavity of the body.
31. The pod of claim 1, wherein the mixing paddle has at least one
blade extending a distance from the axis of the body that is
greater than the radius of the open end of the body.
32. The pod of claim 3, wherein the protrusion has a head, a foot,
and a stem that extends between the head and the foot, the stem
having a smaller cross-section than the head and the foot.
Description
RELATED APPLICATIONS
[0001] This patent application is a continuation-in-part of patent
application U.S. Ser. No. 16/104,758, filed on Aug. 17, 2018 and
claims the benefit of provisional patent applications U.S. Ser. No.
62/758,110, filed on Nov. 9, 2018; U.S. Ser. No. 62/801,587, filed
on Feb. 5, 2019; U.S. Ser. No. 62/831,657, filed on Apr. 9, 2019;
U.S. Ser. No. 62/831,600, filed on Apr. 9, 2019; U.S. Ser. No.
62/831,646, filed on Apr. 9, 2019; and U.S. Ser. No. 62/831,666,
filed on Apr. 9, 2019, all of which are hereby incorporated herein
by reference in their entirety.
TECHNICAL FIELD
[0002] This disclosure relates to systems and methods for rapidly
cooling food and drinks.
BACKGROUND
[0003] Beverage brewing system have been developed that rapidly
prepare single servings of hot beverages. Some of these brewing
systems rely on single use pods to which water is added before
brewing occurs. The pods can be used to prepare hot coffees, teas,
cocoas, and dairy-based beverages.
[0004] Home use ice cream makers can be used to make larger batches
(e.g., 1.5 quarts or more) of ice cream for personal consumption.
These ice cream maker appliances typically prepare the mixture by
employing a hand-crank method or by employing an electric motor
that is used, in turn, to assist in churning the ingredients within
the appliance. The resulting preparation is often chilled using a
pre-cooled vessel that is inserted into the machine.
SUMMARY
[0005] This specification describes systems and methods for rapidly
cooling food and drinks. Some of these systems and methods can cool
food and drinks in a container inserted into a counter-top or
installed machine from room temperature to freezing in less than
two minutes. For example, the approach described in this
specification has successfully demonstrated the ability make
soft-serve ice cream from room-temperature pods in approximately 90
seconds. This approach has also been used to chill cocktails and
other drinks including to produce frozen drinks. These systems and
methods are based on a refrigeration cycle with low startup times
and a pod-machine interface that is easy to use and provides
extremely efficient heat transfer. Some of the pods described are
filled with ingredients in a manufacturing line and subjected to a
sterilization process (e.g., retort, aseptic packaging, ultra-high
temperature processing (UHT), ultra-heat treatment,
ultra-pasteurization, or high pressure processing (HPP)). HPP is a
cold pasteurization technique by which products, already sealed in
its final package, are introduced into a vessel and subjected to a
high level of isostatic pressure (300-600 megapascals (MPa)
(43,500-87,000 pounds per square inch (psi)) transmitted by water.
The pods can be used to store ingredients including, for example,
dairy products at room temperature for long periods of time (e.g.,
9-12 months) following sterilization.
[0006] Cooling is used to indicate the transfer of thermal energy
to reduce the temperature, for example, of ingredients contained in
a pod. In some cases, cooling indicates the transfer of thermal
energy to reduce the temperature, for example, of ingredients
contained in a pod to below freezing.
[0007] Some pods containing at least one ingredient to form a cold
food or drink include: a metal body with a closed end, an open end
opposite the closed end, and a sidewall extending from the closed
end to define an interior cavity of the body; at least one paddle
disposed in the interior cavity of the body and rotatable relative
to the body; and a base extending across the open end of the body,
the base sealed to the sidewall of the body, the base including a
protrusion with a stem that extends between a head and a foot, the
stem having a smaller cross-section than the head and the foot, the
base comprising a weakened section extending around the
protrusion.
[0008] Some cans containing at least one ingredient to form a cold
food or drink include: a metal body with an axis, a closed end, an
open end opposite the closed end, and a sidewall extending from the
closed end to define an interior cavity of the body, the open end
of the body having a radius that is less than an average radius of
the body; at least one paddle extending laterally farther from the
axis of the body than the radius of the open end of the body, the
at least one paddle disposed in the interior cavity of the body and
rotatable relative to the body; and a base extending across the
open end of the body, the base sealed to the sidewall of the body,
the base defining an opening extending through the base
[0009] Some pods for forming a cold food or drink include: a body
with an axis, a first end, a second end opposite the first end, and
a sidewall extending from the first end to define an interior
cavity of the body open at the second end, the second end of the
body having a radius that is less than an average radius of the
body; at least one paddle extending a distance farther from the
axis of the body that is greater than the radius of the open end of
the body, the scraper disposed in the interior cavity of the body;
and a base extending across the open end of the body, the base
sealed to the sidewall of the body, the base defining an opening
extending through the base.
[0010] Some pods containing at least one ingredient to form a cold
food or drink include: a body with a first end, a second end
opposite the first end, and a sidewall extending from the first end
to define an interior cavity of the body open at the second end,
the second end of the body having a radius that is less than an
average radius of the body; a mixing paddle having at least one
blade; a base extending across the open end of the body, the base
sealed to the sidewall of the body, the base defining an opening
extending through the base; and a cap attached to the body, the cap
extending over at least part of the base and rotatable around the
axis of the mixing paddle relative to the base, the cap defining an
opening extending through the cap.
[0011] Pods and cans can include one or more of the following
features.
[0012] In some embodiments, the body and the base of pods form a
can. In some cases, the base includes a protrusion extending
outward relative to adjacent portions of the base, the protrusion
having a stem that extends between a head and a foot, the stem
having a smaller cross-section than the head and the foot, the base
comprising a weakened section extending around the protrusion.
[0013] In some embodiments, pods and cans include a cap attached to
the body, the cap extending over at least part of the base and
rotatable per relative to the base, the cap defining an opening
extending through the cap. In some cases, the cap is rotatable
around the axis of the body. In some cases, cans and pods also
include a plug closing the opening extending through the base. In
some cases, the plug comprises a slide disposed between the cap and
the base, the slide rotatable relative to the base. In some cases,
the plug comprises a foil seal and the cap is positioned to engage
and remove the foil seal from the opening defined extending through
the base on rotation of the cap.
[0014] In some embodiments, pods and cans include a peel-off lid
extending over the cap. In some cases, the at least one blade is a
plurality of blades. In some cases, each blade has two or more
different angles of inclination relative to a plane perpendicular
to the axis of the body. In some cases, the plurality of paddles
are configured to be resilient enough to resume an original shape
after being compressed to fit through the open end of the body. In
some cases, the at least one paddle has grooves in an outer edge,
the grooves sized to receive a rim of the open end of the body to
enable insertion of the scraper into the interior cavity of the
body by rotation of the scraper with the rim in the grooves.
[0015] In some embodiments, pods and cans include a vessel
containing pressurized gas disposed in the interior cavity of the
body. In some cases, the pod is internally pressurized to at least
20 psi.
[0016] In some embodiments, pods and cans include between 3 and 10
ounces of the at least one ingredient.
[0017] The systems and methods described in this specification can
provide a number of advantages. Some embodiments of these systems
and methods can provide single servings of cooled food or drink.
This approach can help consumers with portion control. Some
embodiments of these systems and methods can provide consumers the
ability to choose their single-serving flavors, for example, of
soft serve ice cream. Some embodiments of these systems and methods
incorporate shelf-stable pods that do not require pre-cooling,
pre-freezing or other preparation. Some embodiments of these
systems and methods can generate frozen food or drinks from
room-temperature pods in less than two minutes (in some cases, less
than one minute). Some embodiments of these systems and methods do
not require post-processing clean up once the cooled or frozen food
or drink is generated. Some embodiments of these systems and
methods utilize aluminum pods that are recyclable.
[0018] The details of one or more embodiments of these systems and
methods are set forth in the accompanying drawings and the
description below. Other features, objects, and advantages of these
systems and methods will be apparent from the description and
drawings, and from the claims.
DESCRIPTION OF FIGURES
[0019] FIG. 1A is a perspective view of a machine for rapidly
cooling food and drinks. FIG. 1B shows the machine without its
housing.
[0020] FIG. 1C is a perspective view of a portion of the machine of
FIG. 1A.
[0021] FIG. 2A is perspective view of the machine of FIG. 1A with
the cover of the pod-machine interface illustrated as being
transparent to allow a more detailed view of the evaporator to be
seen. FIG. 2B is a top view of a portion of the machine without the
housing and the pod-machine interface without the lid. FIGS. 2C and
2D are, respectively, a perspective view and a side view of the
evaporator.
[0022] FIGS. 3A-3F show components of a pod-machine interface that
are operable to open and close pods in the evaporator to dispense
the food or drink being produced.
[0023] FIG. 4 is a schematic of a refrigeration system.
[0024] FIGS. 5A and 5B are views of a prototype of a condenser.
[0025] FIG. 6A is a side view of a pod. FIG. 6B is a schematic side
view of the pod and a mixing paddle disposed in the pod.
[0026] FIGS. 7A and 7B are perspective views of a pod and an
associated drive shaft. FIG. 7C is a cross-section of a portion of
the pod with the drive shaft engaged with a mixing paddle in the
pod.
[0027] FIG. 8 shows a first end of a pod with its cap spaced apart
from its base for ease of viewing. FIGS. 9A-9G illustrate rotation
of a cap around the first end of the pod to open an aperture
extending through the base.
[0028] FIG. 10 is an enlarged schematic side view of a pod.
[0029] FIG. 11 is a flow chart of a method for operating a machine
for producing cooled food or drinks.
[0030] FIG. 12A is a front view of a pod that has a volume of
twelve fluid ounces. FIG. 12B is a schematic view of the pod of
FIG. 12A. FIG. 12C is a front view of a pod that has a volume of
eight fluid ounces.
[0031] FIGS. 13A and 13B show the pod of FIG. 12B before and after
freezing.
[0032] FIG. 14 is a perspective view of a first end of a pod with a
detachable paddle interface.
[0033] FIGS. 15A and 15B are, respectively a perspective view and a
cross-sectional view of a pod in an evaporator.
[0034] 16 is a schematic view illustrating a threaded plug and a
complimentary threaded recess defined in the central stem of a
mixing paddle.
[0035] FIGS. 17A-17C are perspective views of a plate mounted to
the first end of a pod. FIGS. 17D and 17E are perspective views of
the first end of the pod.
[0036] FIG. 18A is a perspective view of a rotatable base on the
first end of a pod. FIGS. 18B-18D are perspective views of the
rotatable base.
[0037] FIGS. 19A and 19B show a plate rotatably connected to the
first end of a pod.
[0038] FIGS. 20A and 20B are views of a plate disposed on the first
end of a pod.
[0039] FIG. 21A is a perspective view of a pod with the second end
connected to a cap and a slider disposed between the pod and the
cap. FIGS. 21B and 21C are exploded views of the pod, the cap, and
the slider aligned to be in their closed position.
[0040] FIGS. 21D and 21E show the plug portion of the slider in the
dispensing port. FIGS. 21F and 21G are, respectively, an exploded
view and a bottom view of the cap and slider in their open
position.
[0041] FIGS. 22A and 22B are schematic views of a pod engaged with
a rotator.
[0042] FIGS. 23A and 23B are schematic views of a pod engaged with
a rotator.
[0043] FIGS. 24A and 24B are perspective views of a removable lid
that covers an end of a pod.
[0044] FIGS. 25A-25C are, respectively, a perspective view, a
cross-sectional view, and a top-down view of a pod-machine
interface with an evaporator.
[0045] FIGS. 26A and 26B are, respectively, a perspective view and
a cutaway view of a pod.
[0046] FIG. 27 is a perspective view of a mixing paddle.
[0047] FIG. 28 is a perspective view of a mixing paddle.
[0048] FIG. 29A is a perspective view of a mixing paddle. FIG. 29B
is a schematic view illustrating insertion of the mixing paddle of
FIG. 29A into a pod.
[0049] FIG. 30A is a perspective view of a mixing paddle. FIG. 30B
is a schematic view illustrating insertion of the mixing paddle of
FIG. 30A into a pod.
[0050] FIG. 31 is a perspective view of a mixing paddle.
[0051] FIG. 32A is a perspective view of a mixing paddle. FIGS. 32B
and 32C are schematic views illustrating insertion of the mixing
paddle of FIG. 32A into a pod.
[0052] FIG. 33 is a perspective view of a mixing paddle.
[0053] FIG. 34A is a perspective view of a mixing paddle. FIGS.
34B-34D are schematic views illustrating insertion of the mixing
paddle of FIG. 34A into a pod.
[0054] FIG. 35 is a perspective view of a mixing paddle.
[0055] FIG. 36A is a perspective view of a mixing paddle. FIGS.
36B-36D are schematic views illustrating insertion of the mixing
paddle of FIG. 36A into a pod.
[0056] FIG. 37A is a perspective view of a mixing paddle. FIG. 374B
is a schematic view illustrating insertion of the mixing paddle of
FIG. 37A into a pod.
[0057] FIG. 38 is a perspective view of a mixing paddle.
[0058] FIG. 39 is a perspective view of a mixing paddle.
[0059] FIG. 40 is a perspective view of a mixing paddle.
[0060] FIG. 41 is a perspective view of a mixing paddle in a
pod.
[0061] FIGS. 42A and 42B illustrate an approach to filling a
pod.
[0062] FIGS. 43A and 43B shows a pod with a removable internal
paddle.
[0063] FIGS. 44A and 44B show a pod with an upper casing for
storing toppings.
[0064] FIGS. 45A and 45B show a gas-releasing disk housed,
respectively, in a paddle and in a pod.
[0065] FIGS. 46A, 46B, and 46C are, respectively, a perspective
cutaway view, a side view, and an exploded view of a stack of
bases.
[0066] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0067] This specification describes systems and methods for rapidly
cooling food and drinks. Some of these systems and methods use a
counter-top or installed machine to cool food and drinks in a
container from room temperature to freezing in less than two
minutes. For example, the approach described in this specification
has successfully demonstrated the ability make soft-serve ice
cream, frozen coffees, frozen smoothies, and frozen cocktails, from
room temperature pods in approximately 90 seconds. This approach
can also be used to chill cocktails, create frozen smoothies,
frozen protein and other functional beverage shakes (e.g.,
collagen-based, energy, plant-based, non-dairy, CBD shakes), frozen
coffee drinks and chilled coffee drinks with and without nitrogen
in them, create hard ice cream, create milk shakes, create frozen
yogurt and chilled probiotic drinks. These systems and methods are
based on a refrigeration cycle with low startup times and a
pod-machine interface that is easy to use and provides extremely
efficient heat transfer. Some of the pods described can be
sterilized (e.g., using retort sterilization) and used to store
ingredients including, for example, dairy products at room
temperature for up to 18 months.
[0068] FIG. 1A is a perspective view of a machine 100 for cooling
food or drinks. FIG. 1B shows the machine without its housing. The
machine 100 reduces the temperature of ingredients in a pod
containing the ingredients. Most pods include a mixing paddle used
to mix the ingredients before dispensing the cooled or frozen
products. The machine 100 includes a body 102 that includes a
compressor, condenser, fan, evaporator, capillary tubes, control
system, lid system and dispensing system with a housing 104 and a
pod-machine interface 106. The pod-machine interface 106 includes
an evaporator 108 of a refrigeration system 109 whose other
components are disposed inside the housing 104. As shown on FIG.
1B, the evaporator 108 defines a receptacle 110 sized to receive a
pod.
[0069] A lid 112 is attached to the housing 104 via a hinge 114.
The lid 112 can rotate between a closed position covering the
receptacle 110 (FIG. 1A) and an open position exposing the
receptacle 110 (FIG. 1B). In the closed position, the lid 112
covers the receptacle 110 and is locked in place. In the machine
100, a latch 116 on the lid 112 engages with a latch recess 118 on
the pod-machine interface 106. A latch sensor 120 is disposed in
the latch recess 118 to determine if the latch 116 is engaged with
the latch recess 118. A processor 122 is electronically connected
to the latch sensor 120 and recognizes that the lid 112 is closed
when the latch sensor 120 determines that the latch 116 and the
latch recess 118 are engaged.
[0070] An auxiliary cover 115 rotates upward as the lid 112 is
moved from its closed position to its open position. A slot in the
auxiliary cover 115 receives a handle of the lid 112 during this
movement. Some auxiliary covers slide into the housing when the lid
moves into the open position.
[0071] In the machine 100, the evaporator 108 is fixed in position
with respect to the body 102 of the machine 100 and access to the
receptacle 110 is provided by movement of the lid 112. In some
machines, the evaporator 108 is displaceable relative to the body
102 and movement of the evaporator 108 provides access to the
receptacle 110.
[0072] A motor 124 disposed in the housing 104 is mechanically
connected to a drive shaft 126 that extends from the lid 112. When
the lid 112 is in its closed position, the drive shaft 126 extends
into the receptacle 110 and, if a pod is present, engages with the
pod to move a paddle or paddles within the pod. The processor 122
is in electronic communication with the motor 124 and controls
operation of the motor 124. In some machines, the shaft associated
with the paddle(s) of the pod extends outward from the pod and the
lid 112 has a rotating receptacle (instead of the drive shaft 126)
mechanically connected to the motor 124.
[0073] FIG. 1C is perspective view of the lid 112 shown separately
so the belt 125 that extends from motor 124 to the drive shaft 126
is visible. Referring again to FIG. 1B, the motor 124 is mounted on
a plate that runs along rails 127. The plate can move approximately
0.25 inches to adjust the tension on the belt. During assembly, the
plate slides along the rails. Springs disposed between the plate
and the lid 112 bias the lid 112 away from the plate to maintain
tension in the belt.
[0074] FIG. 2A is a perspective view of the machine 100 with the
cover of the pod-machine interface 106 illustrated as being
transparent to allow a more detailed view of the evaporator 108 to
be seen. FIG. 2B is a top view of a portion of the machine 100
without housing 104 and the pod-machine interface 106 without the
lid 112. FIGS. 2C and 2D are, respectively, a perspective view and
a side view of the evaporator 108. The evaporator 108 is described
in more detail in U.S. patent application Ser. No. ______ (attorney
docket number 47354-0006001) filed contemporaneously with this
application and incorporated herein by reference in its entirety.
This application also describes other evaporators and heat exchange
systems that can be used in machines to cool food and drink in
pods. Other pod-machine interfaces that can be used in this and
other machines are described in U.S. patent application Ser. No.
______ (attorney docket number 47354-0009001) filed
contemporaneously with this application and incorporated herein by
reference in its entirety.
[0075] The evaporator 108 has a clamshell configuration with a
first portion 128 attached to a second portion 130 by a living
hinge 132 on one side and separated by a gap 134 on the other side.
Refrigerant flows to the evaporator 108 from other components of
the refrigeration system through fluid channels 136 (best seen on
FIG. 2B). The refrigerant flows through the evaporator 108 in
internal channels through the first portion 128, the living hinge
132, and the second portion 130.
[0076] The space 137 (best seen on FIG. 2B) between the outer wall
of the evaporator 108 and the inner wall of the casing of the
pod-machine interface 106 is filled with an insulating material to
reduce heat exchange between the environment and the evaporator
108. In the machine 100, the space 137 is filled with an aerogel
(not shown). Some machines use other insulating material, for
example, an annulus (such as an airspace), insulating foams made of
various polymers, or fiberglass wool.
[0077] The evaporator 108 has an open position and a closed
position. In the open position, the gap 134 provides an air gap
between the first portion 128 and the second portion 130. In the
machine 100, the first portion 128 and the second portion 130 are
pressed together in the closed position. In some machines, the
first and second portion are pressed towards each other and the gap
is reduced, but still defined by a space between the first and
second portions in the closed position.
[0078] The inner diameter ID of the evaporator 108 is slightly
larger in the open position than in the closed position. Pods can
be inserted into and removed from the evaporator 108 while the
evaporator is in the open position. Transitioning the evaporator
108 from its open position to its closed position after a pod is
inserted tightens the evaporator 108 around the outer diameter of
the pod. For example, the machine 100 is configured to use pods
with 2.085'' outer diameter. The evaporator 108 has an inner
diameter of 2.115'' in the open position and an inner diameter
inner diameter of 2.085'' in the closed position. Some machines
have evaporators sized and configured to cool other pods. The pods
can be formed from commercially available can sizes, for example,
"slim" cans with diameters ranging from 2.080 inches-2.090 inches
and volumes of 180 milliliters (ml)-300 ml, "sleek" cans with
diameters ranging from 2.250 inches-2.400 inches and volumes of 180
ml-400 ml and "standard" size cans with diameters ranging from
2.500 inches-2.600 inches and volumes of 200 ml-500 ml. The machine
100 is configured to use pods with 2.085 inches outer diameter. The
evaporator 108 has an inner diameter of 2.115 inches in its open
position and an inner diameter inner diameter of 2.085 inches in
its closed position. Some machines have evaporators sized and
configured to cool other pods. Standard cans are typically formed
with a body having a closed end and sidewalls formed from a single
piece of metal. Typically, the can is filled and then a separately
formed base is attached across the open end of the body.
[0079] The closed position of evaporator 108 improves heat transfer
between inserted pod 150 and the evaporator 108 by increasing the
contact area between the pod 150 and the evaporator 108 and
reducing or eliminating an air gap between the wall of the pod 150
and the evaporator 108. In some pods, the pressure applied to the
pod by the evaporator 108 is opposed by the mixing paddles,
pressurized gases within the pod, or both to maintain the casing
shape of the pod.
[0080] In the evaporator 108, the relative position of the first
portion 128 and the second portion 130 and the size of the gap 134
between them is controlled by two bars 138 connected by a bolt 140
and two springs 142. Each of the bars 138 has a threaded central
hole through which the bolt 140 extends and two end holes engaging
the pins 144. Each of the two springs 142 is disposed around a pin
144 that extends between the bars 138. Some machines use other
systems to control the size of the gap 134, for example,
circumferential cable systems with cables that extend around the
outer diameter of the evaporator 108 with the cable being tightened
to close the evaporator 108 and loosened to open the evaporator
108. In other evaporators, there are a plurality of bolts and end
holes, one or more than two springs, and one or more than engaging
pins.
[0081] One bar 138 is mounted on the first portion 128 of the
evaporator 108 and the other bar 138 is mounted on the second
portion 130 of the evaporator 108. In some evaporators, the bars
138 are integral to the body of the evaporator 108 rather than
being mounted on the body of the evaporator. The springs 142 press
the bars 138 away from each other. The spring force biases the
first portion 128 and the second portion 130 of the evaporator 108
away from each at the gap 134. Rotation of the bolt 140 in one
direction increases a force pushing the bars 138 towards each and
rotation of the bolt in the opposite direction decreases this
force. When the force applied by the bolt 140 is greater than the
spring force, the bars 138 bring the first portion 128 and the
second portion 130 of the evaporator together.
[0082] The machine 100 includes an electric motor 146 (shown on
FIG. 2B) that is operable to rotate the bolt 140 to control the
size of the gap 134. Some machines use other mechanisms to rotate
the bolt 140. For example, some machines use a mechanical linkage,
for example, between the lid 112 and the bolt 140 to rotate the
bolt 140 as the lid 112 is opened and closed. Some machines include
a handle that can be attached to the bolt to manually tighten or
loosen the bolt. Some machines have a wedge system that forces the
bars into a closed position when the machine lid is shut. This
approach may be used instead of the electric motor 146 or can be
provided as a backup in case the motor fails.
[0083] The electric motor 146 is in communication with and
controlled by the processor 122 of the machine 100. Some electric
drives include a torque sensor that sends torque measurements to
the processor 122. The processor 122 signals to the motor to rotate
the bolt 140 in a first direction to press the bars 138 together,
for example, when a pod sensor indicates that a pod is disposed in
the receptacle 110 or when the latch sensor 120 indicates that the
lid 112 and pod-machine interface 106 are engaged. It is desirable
that the clamshell evaporator be shut and holding the pod in a
tightly fixed position before the lid closes and the shaft pierces
the pod and engages the mixing paddle. This positioning can be
important for drive shaft-mixing paddle engagement. The processor
122 signals to the electric drive to rotate the bolt 140 in the
second direction, for example, after the food or drink being
produced has been cooled/frozen and dispensed from the machine 100,
thereby opening the evaporator gap 134 and allowing for easy
removal of pod 150 from evaporator 108
[0084] The base of the evaporator 108 has three bores 148 (see FIG.
2C) which are used to mount the evaporator 108 to the floor of the
pod-machine interface 106. All three of the bores 148 extend
through the base of the second portion 130 of the evaporator 108.
The first portion 128 of the evaporator 108 is not directly
attached to the floor of the pod-machine interface 106. This
configuration enables the opening and closing movement described
above. Other configurations that enable the evaporator 108 opening
and closing movement can also be used. Some machines have more or
fewer than three bores 148. Some evaporators are mounted to
components other than the floor of the pod-machine interface, for
example, the dispensing mechanism.
[0085] FIGS. 3A-3F show components of the pod-machine interface 106
that are operable to open pods in the evaporator 108 to dispense
the food or drink being produced by the machine 100. This is an
example of one approach to opening pods but some machines and the
associated pods use other approaches.
[0086] FIG. 3A is a partially cutaway schematic view of the
pod-machine interface 106 with a pod 150 placed in the evaporator
108. FIG. 3B is a schematic plan view looking upwards that shows
the relationship between the end of the pod 150 and the floor 152
of the pod-machine interface 106. The floor 152 of the pod-machine
interface 106 is formed by a dispenser 153. FIGS. 3C and 3D are
perspective views of a dispenser 153. FIGS. 3E and 3F are
perspective views of an insert 154 that is disposed in the
dispenser 153. The insert 154 includes an electric motor 146
operable to drive a worm gear 157 floor 152 of the pod-machine
interface 106. The worm gear 157 is engaged with a gear 159 with an
annular configuration. An annular member 161 mounted on the gear
159 extends from the gear 159 into an interior region of the
pod-machine interface 106. The annular member 161 has protrusions
163 that are configured to engage with a pod inserted into the
pod-machine interface 106 to open the pod. The protrusions 163 of
the annular member 161 are four dowel-shaped protrusions. Some
annular gears have more protrusions or fewer protrusions and the
protrusions can have other shapes, for example, "teeth."
[0087] The pod 150 includes a body 158 containing a mixing paddle
160 (see FIG. 3A). The pod 150 also has a base 162 defining an
aperture 164 and a cap 166 extending across the base 162 (see FIG.
3B). The base 162 is seamed/fixed onto the body 158 of the pod 150.
The base 162 includes a protrusion 165. The cap 166 mounted over
base 162 is rotatable around the circumference/axis of the pod 150.
In use, when the product is ready to be dispensed from the pod 150,
the dispenser 153 of the machine engages and rotates the cap 166
around the first end of the pod 150. Cap 166 is rotated to a
position to engage and then separate the protrusion 165 from the
rest of the base 162. The pod 150 and its components are described
in more detail with respect to FIGS. 6A-10.
[0088] The aperture 164 in the base 162 is opened by rotation of
the cap 166. The pod-machine interface 106 includes an electric
motor 146 with threading that engages the outer circumference of a
gear 168. Operation of the electric motor 146 causes the gear 168
to rotate. The gear 168 is attached to a annular member 161 and
rotation of the gear 168 rotates the annular member 161. The gear
168 and the annular member 161 are both annular and together define
a central bore through which food or drink can be dispensed from
the pod 150 through the aperture 164 without contacting the gear
168 or the annular member 161. When the pod 150 is placed in the
evaporator 108, the annular member 161 engages the cap 166 and
rotation of the annular member 161 rotates the cap 166.
[0089] FIG. 4 is a schematic of the refrigeration system 109 that
includes the evaporator 108. The refrigeration system also includes
a condenser 180, a suction line heat exchanger 182, an expansion
valve 184, and a compressor 186. High-pressure, liquid refrigerant
flows from the condenser 180 through the suction line heat
exchanger 182 and the expansion valve 184 to the evaporator 108.
The expansion valve 184 restricts the flow of the liquid
refrigerant fluid and lowers the pressure of the liquid refrigerant
as it leaves the expansion valve 184. The low-pressure liquid then
moves to the evaporator 108 where heat absorbed from a pod 150 and
its contents in the evaporator 108 changes the refrigerant from a
liquid to a gas. The gas-phase refrigerant flows from the
evaporator 108 to the compressor 186 through the suction line heat
exchanger 182. In the suction line heat exchanger 182, the liquid
refrigerant cools gas-phase refrigerant before it enters the
compressor 186. The refrigerant enters the compressor 186 as a
low-pressure gas and leaves the compressor 186 as a high-pressure
gas. The gas then flows to the condenser 180 where heat exchange
cools and condenses the refrigerant to a liquid.
[0090] The refrigeration system 109 includes a first bypass line
188 and second bypass line 190. The first bypass line 188 directly
connects the discharge of the compressor 186 to the inlet of the
compressor 186. Diverting the refrigerant directly from the
compressor discharge to the inlet can provide evaporator defrosting
and temperature control without injecting hot gas to the evaporator
that could reduce flow to the evaporator, increase the pressure in
the evaporator and, in turn, raise the evaporator temperature above
freezing. The first bypass line 188 also provides a means for rapid
pressure equalization across the compressor 186, which allows for
rapid restarting (i.e., freezing one pod after another quickly).
The second bypass line 190 enables the application of warm gas to
the evaporator 108 to defrost the evaporator 108.
[0091] FIGS. 5A and 5B are views of a prototype of the condenser
180. The condenser has internal channels 192. The internal channels
192 increase the surface area that interacts with the refrigerant
cooling the refrigerant quickly. These images show micro-channel
tubing which are used because they have small channels which keeps
the coolant velocity up and are thin wall for good heat transfer
and have little mass to prevent the condenser for being a heat
sink.
[0092] FIGS. 6A and 6B show an example of a pod 150 for use with
the machine 100 described with respect to FIGS. 1A-3F. FIG. 6A is a
side view of the pod 150. FIG. 6B is a schematic side view of the
pod 150 and the mixing paddle 160 disposed in the body 158 of the
pod 150.
[0093] The pod 150 is sized to fit in the receptacle 110 of the
machine 100. The pods can be sized to provide a single serving of
the food or drink being produced. Typically, pods have a volume
between 6 and 18 fluid ounces. The pod 150 has a volume of
approximately 8.5 fluid ounces.
[0094] The body 158 of the pod 150 is a can that contains the
mixing paddle 160. The body 158 extends from a first end 210 at the
base to a second end 212 and has a circular cross-section. The
first end 210 has a diameter D.sub.UE that is slightly larger than
the diameter D.sub.LE of the second end 212. This configuration
facilitates stacking multiple pods 200 on top of one another with
the first end 210 of one pod receiving the second end 212 of
another pod.
[0095] A wall 214 connects the first end 210 to the second end 212.
The wall 214 has a first neck 216, second neck 218, and a barrel
220 between the first neck 216 and the second neck 218. The barrel
220 has a circular cross-section with a diameter D.sub.B. The
diameter D.sub.B is larger than both the diameter D.sub.UE of the
first end 210 and the diameter D.sub.LE of the second end 212. The
first neck 216 connects the barrel 220 to the first end 210 and
slopes as the first neck 216 extends from the smaller diameter
D.sub.UE to the larger diameter D.sub.B the barrel 220. The second
neck 218 connects the barrel 220 to the second end 212 and slopes
as the second neck 218 extends from the larger diameter D.sub.B of
the barrel 220 to the smaller diameter D.sub.LE of the second end
212. The second neck 218 is sloped more steeply than the first neck
216 as the second end 212 has a smaller diameter than the first end
210.
[0096] This configuration of the pod 150 provides increased
material usage; i.e., the ability to use more base material (e.g.,
aluminum) per pod. This configuration further assists with the
columnar strength of the pod.
[0097] The pod 150 is designed for good heat transfer from the
evaporator to the contents of the pod. The body 158 of the pod 150
is made of aluminum and is between 5 and 50 microns thick. The
bodies of some pods are made of other materials, for example, tin,
stainless steel, and various polymers such as Polyethylene
terephthalate (PTE).
[0098] Pod 150 may be made from a combination of different
materials to assist with the manufacturability and performance of
the pod. In one embodiment, the pod walls and the second end 212
may be made of Aluminum 3104 while the base may be made of Aluminum
5182.
[0099] In some pods, the internal components of the pod are coated
with a lacquer to prevent corrosion of the pod as it comes into
contact with the ingredients contained within pod. This lacquer
also reduces the likelihood of "off notes" of the metal in the food
and beverage ingredients contained within pod. For example, a pod
made of aluminum may be internally coated with one or a combination
of the following coatings: Sherwin Williams/Valspar V70Q11, V70Q05,
32SO2AD, 40Q60AJ; PPG Innovel 2012-823, 2012-820C; and/or Akzo
Nobel Aqualure G1 50. Other coatings made by the same or other
coating manufacturers may also be used.
[0100] Some mixing paddles are made of similar aluminum alloys and
coated with similar lacquers/coatings. For example, Whitford/PPG
coating 8870 may be used as a coating for mixing paddles. The
mixing paddle lacquer may have additional non-stick and hardening
benefits for mixing paddle.
[0101] FIGS. 7A-7C illustrate the engagement between the drive
shaft 126 of the machine 100 and the mixing paddle 160 of a pod 150
inserted in the machine 100. FIGS. 7A and 7B are perspective views
of the pod 150 and the drive shaft 126. In use, the pod 150 is
inserted into the receptacle 110 of the evaporator 108 with the
first end 210 of the pod 150 downward. This orientation exposes the
second end 212 of the pod 150 to the drive shaft 126 as shown in
FIG. 7A. Closing the lid 112 (see FIG. 1A) presses the drive shaft
126 against the second end 212 of the pod 150 with sufficient force
that the drive shaft 126 pierces the second end 212 of the pod 150.
FIG. 7B shows the resulting hole exposing the mixing paddle 160
with the drive shaft 126 offset for ease of viewing. FIG. 7C is a
cross-section of a portion of the pod 150 with the drive shaft 126
engaged with the mixing paddle 160 after the lid is closed.
Typically, there is not a tight seal between the drive shaft 126
and the pod 150 so that air can flow in as the frozen confection is
evacuating/dispensing out the other end of the pod 150. In an
alternative embodiment, there is a tight seal such that the pod 150
retains pressure in order to enhance contact between the pod 150
and evaporator 108.
[0102] Some mixing paddle contain a funnel or receptacle
configuration that receives the punctured end of the second end of
the pod when the second end is punctured by driveshaft.
[0103] FIG. 8 shows the first end 210 of the pod 150 with the cap
166 spaced apart from the base 162 for ease of viewing. FIGS. 9A-9G
illustrate rotation of the cap 166 around the first end 210 of the
pod 150 to cut and carry away protrusion 165 of base 162 and expose
aperture 164 extending through the base 162.
[0104] The base 162 is manufactured separately from the body 158 of
the pod 150 and then attached (for example, by crimping or seaming)
to the body 158 of the pod 150 covering an open end of the body
158. The protrusion 165 of the base 162 can be formed, for example,
by stamping, deep drawing, or heading a sheet of aluminum being
used to form the base. The protrusion 165 is attached to the
remainder of the base 162, for example, by a weakened score line
173. The scoring can be a vertical score into the base of the
aluminum sheet or a horizontal score into the wall of the
protrusion 165. For example, the material can be scored from an
initial thickness of 0.008 inches to 0.010 inches to a post-scoring
thickness of 0.001 inches-0.008 inches. In an alternative
embodiment, there is no post-stamping scoring but rather the walls
are intentionally thinned for ease of rupture. In another version,
there is not variable wall thickness but rather the cap 166
combined with force of the machine dispensing mechanism engagement
are enough to cut the 0.008 inches to 0.010 inches wall thickness
on the protrusion 165. With the scoring, the protrusion 165 can be
lifted and sheared off the base 162 with 5-75 pounds of force, for
example between 15-40 pounds of force.
[0105] The cap 166 has a first aperture 222 and a second aperture
224. The first aperture approximately matches the shape of the
aperture 164. The aperture 164 is exposed and extends through the
base 162 when the protrusion 165 is removed. The second aperture
224 has a shape corresponding to two overlapping circles. One of
the overlapping circles has a shape that corresponds to the shape
of the protrusion 165 and the other of the overlapping circles is
slightly smaller. A ramp 226 extends between the outer edges of the
two overlapping circles. There is an additional 0.020'' material
thickness at the top of the ramp transition. This extra height
helps to lift and rupture the protrusion's head and open the
aperture during the rotation of the cap as described in more detail
with reference to FIGS. 9A-9G.
[0106] As shown in FIGS. 9A and 9B, the cap 166 is initially
attached to the base 162 with the protrusion 165 aligned with and
extending through the larger of the overlapping circles of the
second aperture 224. When the processor 122 of the machine
activates the electric motor 146 to rotate the gear 168 and the
annular member 161, rotation of the cap 166 slides the ramp 226
under a lip of the protrusion 165 as shown in FIGS. 9C and 9D.
Continued rotation of the cap 166 applies a lifting force that
separates the protrusion 165 from the remainder of the base 162
(see FIGS. 9E-9G) and then aligns the first aperture 222 of the cap
166 with the aperture 164 in the base 162 resulting from removal of
the protrusion 165.
[0107] Some pods include a structure for retaining the protrusion
165 after the protrusion 165 is separated from the base 162. In the
pod 150, the protrusion 165 has a head 167, a stem 169, and a foot
171 (best seen in FIG. 9G). The stem 169 extends between the head
167 and the foot 171 and has a smaller cross-section that the head
167 and the foot 171. As rotation of the cap 166 separates the
protrusion 165 from the remainder of the base 162, the cap 166
presses laterally against the stem 169 with the head 167 and the
foot 171 bracketing the cap 166 along the edges of one of the
overlapping circles of the second aperture 224. This configuration
retains the protrusion 165 when the protrusion 165 is separated
from the base 166. Such a configuration reduces the likelihood that
the protrusion falls into the waiting receptacle that when the
protrusion 165 is removed from the base.
[0108] Some pods include other approaches to separating the
protrusion 165 from the remainder of the base 162. For example, in
some pods, the base has a rotatable cutting mechanism that is
riveted to the base. The rotatable cutting mechanism has a shape
similar to that described relative to cap 166 but this secondary
piece is riveted to and located within the perimeter of base 162
rather than being mounted over and around base 162. When the
refrigeration cycle is complete, the processor 122 of the machine
activates an arm of the machine to rotate the riveted cutting
mechanism around a rivet. During rotation, the cutting mechanism
engages, cuts and carries away the protrusion 165, leaving the
aperture 164 of base 162 in its place.
[0109] In another example, some pods have caps with a sliding knife
that moves across the base to remove the protrusion. The sliding
knife is activated by the machine and, when triggered by the
controller, slides across the base to separate, remove, and collect
the protrusion 165. The cap 166 has a guillotine feature that, when
activated by the machine, may slide straight across and over the
base 162. The cap 166 engages, cuts, and carries away the
protrusion 165. In another embodiment, this guillotine feature may
be central to the machine and not the cap 166 of pod 150. In
another embodiment, this guillotine feature may be mounted as a
secondary piece within base 162 and not a secondary mounted piece
as is the case with cap 166.
[0110] Some pods have a dispensing mechanism that includes a pop
top that can be engaged and released by the machine. When the
refrigeration cycle is complete, an arm of the machine engages and
lifts a tab of the pod, thereby pressing the puncturing the base
and creating an aperture in the base. Chilled or frozen product is
dispensed through the aperture. The punctured surface of the base
remains hinged to base and is retained inside the pod during
dispensing. The mixing avoids or rotates over the punctured surface
or, in another embodiment, so that the mixing paddle continues to
rotate without obstruction. In some pop tops, the arm of the
machine separates the punctured surface from the base.
[0111] FIG. 10 is an enlarged schematic side view of the pod 150.
The mixing paddle 160 includes a central stem 228 and two blades
230 extending from the central stem 228. The blades 230 are helical
blades shaped to churn the contents of the pod 150 and to remove
ingredients that adhere to inner surface of the body 158 of the pod
150. Some mixing paddles have a single blade and some mixing
paddles have more than two mixing paddles.
[0112] Fluids (for example, liquid ingredients, air, or frozen
confection) flow through openings 232 in the blades 230 when the
mixing paddle 160 rotates. These openings reduce the force required
to rotate the mixing paddle 160. This reduction can be significant
as the viscosity of the ingredients increases (e.g., as ice cream
forms). The openings 232 further assist in mixing and aerating the
ingredients within the pod.
[0113] The lateral edges of the blades 230 define slots 234. The
slots 234 are offset so that most of the inner surface of the body
158 is cleared of ingredients that adhere to inner surface of the
body by one of the blades 230 as the mixing paddle 160 rotates.
Although the mixing paddle is 160 wider than the first end 210 of
the body 158 of the pod 150, the slots 234 are alternating slots
that facilitate insertion of the mixing paddle 160 into the body
158 of the pod 150 by rotating the mixing paddle 160 during
insertion so that the slots 234 are aligned with the first end 210.
In another embodiment, the outer diameter of the mixing paddle are
less than the diameter of the pod 150 opening, allowing for a
straight insertion (without rotation) into the pod 150. In another
embodiment, one blade on the mixing paddle has an outer-diameter
that is wider than the second blade diameter, thus allowing for
straight insertion (without rotation) into the pod 150. In this
mixing paddle configuration, one blade is intended to remove (e.g.,
scrape) ingredients from the sidewall while the second, shorter
diameter blade, is intended to perform more of a churning
operation.
[0114] Some mixing paddles have one or more blades that are hinged
to the central stem. During insertion, the blades can be hinged
into a condensed formation and released into an expanded formation
once inserted. Some hinged blades are fixed open while rotating in
a first direction and collapsible when rotating in a second
direction, opposite the first direction. Some hinged blades lock
into a fixed, outward, position once inside the pod regardless of
rotational directions. Some hinged blades are manually condensed,
expanded, and locked.
[0115] The mixing paddle 160 rotates clockwise and removes frozen
confection build up from the pod 214 wall. Gravity forces the
confection removed from the pod wall to fall towards first end 210.
In the counterclockwise direction, the mixing paddle 160 rotate,
lift and churn the ingredients towards the second end 212. When the
paddle changes direction and rotates clockwise the ingredients are
pushed towards the first end 210. When the protrusion 165 of the
base 162 is removed as shown and described with respect to FIG. 9D,
clockwise rotation of the mixing paddle dispenses produced food or
drink from the pod 150 through the aperture 164. Some paddles mix
and dispense the contents of the pod by rotating a first direction.
Some paddles mix by moving in a first direction and a second
direction and dispense by moving in the second direction when the
pod is opened.
[0116] The central stem 228 defines a recess 236 that is sized to
receive the drive shaft 126 of the machine 100. The recess and
drive shaft 126 have a square cross section so that the drive shaft
126 and the mixing paddle 160 are rotatably constrained. When the
motor rotates the drive shaft 126, the drive shaft rotates the
mixing paddle 160. In some embodiments, the cross section of the
drive shaft is a different shape and the cross section of the
recess is compatibly shaped. In some cases the drive shaft and
recess are threadedly connected. In some pods, the recess contains
a mating structure that grips the drive shaft to rotationally
couple the drive shaft to the paddle.
[0117] FIG. 11 is a flow chart of a method 250 implemented on the
processor 122 for operating the machine 100. The method 250 is
described with references to refrigeration system 109 and machine
100. The method 250 may also be used with other refrigeration
systems and machines. The method 250 is described as producing soft
serve ice cream but can also be used to produce other cooled or
frozen drinks and foods.
[0118] The first step of the method 250 is to turn the machine 100
on (step 260) and turn on the compressor 186 and the fans
associated with the condenser 180 (step 262). The refrigeration
system 109 then idles at regulated temperature (step 264). In the
method 250, the evaporator 108 temperature is controlled to remain
around 0.75.degree. C. but may fluctuate by .+-.0.25.degree. C.
Some machines are operated at other idle temperatures, for example,
from 0.75.degree. C. to room temperature (22.0.degree. C.). If the
evaporator temperature is below 0.5.degree. C., the processor 122
opens the bypass valve 190 to increase the heat of the system (step
266). When the evaporator temperature goes over 1.degree. C., the
bypass valve 190 is closed to cool the evaporator (step 268). From
the idle state, the machine 100 can be operated to produce ice
cream (step 270) or can shut down (step 272).
[0119] After inserting a pod, the user presses the start button.
When the user presses the start button, the bypass valve 190
closes, the evaporator 108 moves to its closed position, and the
motor 124 is turned on (step 274). In some machines, the evaporator
is closed electronically using a motor. In some machines, the
evaporator is closed mechanically, for example by the lid moving
from the open position to the closed position. In some systems, a
sensor confirms that a pod 150 is present in the evaporator 108
before these actions are taken.
[0120] Some systems include radio frequency identification (RFID)
tags or other intelligent bar codes such as UPC bar or QR codes.
Identification information on pods can be used to trigger specific
cooling and mixing algorithms for specific pods. These systems can
optionally read the RFID, QR code, or barcode and identify the
mixing motor speed profile and the mixing motor torque threshold
(step 273).
[0121] The identification information can also be used to
facilitate direct to consumer marketing (e.g., over the internet or
using a subscription model). This approach and the systems
described in this specification enable selling ice cream thru
e-commerce because the pods are shelf stable. In the subscription
mode, customers pay a monthly fee for a predetermined number of
pods shipped to them each month. They can select their personalized
pods from various categories (e.g., ice cream, healthy smoothies,
frozen coffees or frozen cocktails) as well as their personalized
flavors (e.g., chocolate or vanilla).
[0122] The identification can also be used to track each pod used.
In some systems, the machine is linked with a network and can be
configured to inform a vendor as to which pods are being used and
need to be replaced (e.g., through a weekly shipment). This method
is more efficient than having the consumers go to the grocery store
and purchase pods.
[0123] These actions cool the pod 150 in the evaporator 108 while
rotating the mixing paddle 160. As the ice cream forms, the
viscosity of the contents of the pod 150 increases. A torque sensor
of the machine measures the torque of the motor 124 required to
rotate the mixing paddle 160 within the pod 150. Once the torque of
the motor 124 measured by a torque sensor satisfies a predetermined
threshold, the machine 100 moves into a dispensing mode (276). The
dispensing port opens and the motor 124 reverses direction (step
278) to press the frozen confection out of the pod 150. This
continues for approximately 1 to 10 seconds to dispense the
contents of the pod 150 (step 280). The machine 100 then switches
to defrost mode (step 282). Frost that builds up on the evaporator
108 can reduce the heat transfer efficiency of the evaporator 108.
In addition, the evaporator 108 can freeze to the pod 150, the
first portion 128 and second portion 130 of the evaporator can
freeze together, and/or the pod can freeze to the evaporator. The
evaporator can be defrosted between cycles to avoid these issues by
opening the bypass valve 170, opening the evaporator 108, and
turning off the motor 124 (step 282). The machine then diverts gas
through the bypass valve for about 1 to 10 seconds to defrost the
evaporator (step 284). The machine is programmed to defrost after
every cycle, unless a thermocouple reports that the evaporator 108
is already above freezing. The pod can then be removed. The machine
100 then returns to idle mode (step 264). In some machines, a
thermometer measures the temperature of the contents of pod 150 and
identifies when it is time to dispense the contents of the pod. In
some machines, the dispensing mode begins when a predetermined time
is achieved. In some machines, a combination of torque required to
turn the mixing paddle, temperature of the pod, and/or time
determines when it is time to dispense the contents of the pod.
[0124] If the idle time expires, the machine 100 automatically
powers down (step 272). A user can also power down the machine 100
by holding down the power button (286). When powering down, the
processor opens the bypass valve 190 to equalize pressure across
the valve (step 288). The machine 100 waits ten seconds (step 290)
then turns off the compressor 186 and fans (step 292). The machine
is then off.
[0125] FIG. 12A is a front view of a pod 150 that has a volume of
eight fluid ounces. FIG. 12B is a cross-sectional view of the pod
150 that showing various features whose specifications are
indicated on Table 1.
TABLE-US-00001 TABLE 1 Item Description mm +/- inch +/- A Outside
Body Diameter 53.070 0.01 2.0894 0.0004 B Factory Finished Can
134.09 0.25 5.279 0.010 Height C Dome Depth 9.70 0.13 0.382 0.005 D
Neck Plug Diameter 50.00 0.13 1.969 0.005 E Flange Diameter 54.54
max 2.147 max F Stand Diameter 46.36 ref 1.825 ref G Flange Width
2.10 0.20 0.083 0.008 H Over Flange Radius 1.55 ref 0.061 ref I
Flange Angle 0-7 deg 0-7 deg J Seaming Clearance 3.05 min 0.120 min
K Neck Angle 33.0 deg 33.0 deg L Neck Height 9.80 ref 0.386 ref 1
Dome Reversal Pressure 6.32 Bar 93 PSI (min) 2 Axial Load Strength
(min) 85 KG 834 N 3 Freeboard 14.1 ref 0.56 ref 4 Brimful Capacity
(ml) 279 3 279 3
[0126] Some pods have different volumes and/or shapes. For example,
a pod 300 shown in FIG. 12C has a volume of eight fluid ounces.
Other pods have a volume of 16 fluid ounces. Table 2 includes a
variety of pod volumes and diameters.
TABLE-US-00002 TABLE 2 Volume Volume Diameter Name (milliliters)
(fluid ounces) (Inches) Standard Beverage Pod 1 250 8.45
2.500-2.600 Standard Beverage Pod 2 330 11.15 2.500-2.600 Standard
Beverage Pod 3 355 12.00 2.500-2.600 Standard Beverage Pod 4 375
12.68 2.500-2.600 Standard Beverage Pod 5 440 14.87 2.500-2.600
Standard Beverage Pod 6 500 16.90 2.500-2.600 Slim Pod 1 200 6.76
2.085-2.200 Slim Pod 2 250 8.45 2.085-2.200 Slim Pod 3 300 10.14
2.085-2.200 Sleek Pod 1 300 10.14 2.250-2.400 Sleek Pod 2 350 11.15
2.250-2.400 Sleek Pod 3 355 12.00 2.250-2.400
[0127] FIG. 13A shows the pod 300 before inserting the pod 300 into
the evaporator 108 and FIG. 13B shows the pod 300 after cooling and
before dispensing the contents of the pod 300. In FIG. 13A, the pod
300 includes four fluid ounces of liquid ingredients. The pod 300
can be stored at room temperature or refrigerated prior to
insertion into the evaporator 108. After the pod 300 is inserted
into the evaporator 108, mixed using the internal mixing paddle
160, and cooled to freeze the contents, "loft" associated with the
aeration of the ingredients brings the overall volume of the pod
contents to 5-8 fluid ounces.
[0128] FIG. 14 is a perspective view of the second end 302 of a pod
301. The pod 301 is substantially similar to the pod 150. However,
the second end 302 of the pod 301 includes a paddle interface 304
that is detachable from the body 158. The pod 301 can then be
recycled by separating the plastic mixing paddle (not shown) from
the aluminum body of the pod. The paddle interface 304 detaches by
rotating a flange 306 connected to the central stem of the mixing
paddle. The flange 306 and central stem are translationally coupled
but not rotationally coupled. Rotating the flange 306 unlocks the
paddle from engagement with the pod 301. A user can then pull the
paddle out through a central aperture 308 defined by the second end
302 of the pod 301.
[0129] FIG. 15A is a perspective view and a cross-sectional view of
the pod 150 in the evaporator 108. In FIG. 15A, a cover 315 is
disposed on the evaporator 108. The cover 315 includes a first
fluid inlet 312, a first fluid outlet 314, a second fluid inlet
316, and a second fluid outlet 318. The first fluid inlet 312 and
first fluid outlet 314 are fluidly connected by a first flow path
defined by channels within the first portion 128. The second fluid
inlet 316 and second fluid outlet 318 are fluidly connected by a
second flow path defined by channels within the second portion 130.
The first flow path and the second flow path are independent of
each other.
[0130] FIG. 15B is a cross-sectional view of the evaporator 108 and
pod 150 with mixing paddle 160. The drive shaft 126 passes thru the
second end 212 of the pod 150 and engages the paddle 160 when the
evaporator 108 is in the closed position.
[0131] FIGS. 16-21G show various dispensing mechanisms and
assemblies that can be mounted on or integrated into pods and/or
mixing paddles. The dispensing mechanisms described expose an
opening (e.g., a dispensing port or an aperture) to fluidly connect
the environment with the interior of the pod.
[0132] FIG. 16 is a schematic view of system that includes a
threaded plug 330 and a complimentary threaded recess 332 defined
in the central stem 228 of a mixing paddle. The threaded plug 330
and threaded recess 332 rotate and translate relative to each other
to open an aperture 334 defined in the first end 210 of the pod.
The plug 330 abuts the stem 228 such that rotation in a
counter-clockwise direction engages the threads on the plug 330
with the threaded recess 332. Further rotation of the central stem
228 pulls the plug 330 into the recess 332, eventually exposing the
aperture 334 defined in the first end 210 of the pod.
Counter-clockwise rotation of the paddle 160 churns the contents of
the pod downwards, through the aperture 334. Clockwise rotation of
the mixing paddle 160 churns the contents of the pod upwards, away
from the aperture 334. Initially the plug 330 and recess 332 abut
in such a manner that the when the paddle 160 rotates clockwise,
the threaded plug 330 and the threaded recess 332 do not engage
each other.
[0133] FIGS. 17A-17C are perspective views of a cap 336 rotatably
mounted to the first end 210 of a pod. A foil seal 338 covers a
dispensing port 340 defined in the first end 210 of the pod. The
cap 336 defines an opening 342 sized similarly to the dispensing
port 340. A scraper is used to remove the foil when it is time to
dispense the contents of the pod. The cap 336 has a knife-edge 344
that functions as the scraper.
[0134] The cap 336 and foil 338 are initially positioned as shown
in FIG. 17A. When the contents of the pod are ready to be
dispensed, the machine 100 rotates the cap 336 in a
counterclockwise direction. As the cap 336 rotates, the knife-edge
344 scrapes and detaches the foil seal 338 from first end 210,
exposing the dispensing port 340 as shown in FIG. 17B. An arm 346
projects from the cap 336 to engage the detached seal 338 and keep
it from falling into the food or drink being dispensed. The cap 336
continues to rotate in a counterclockwise direction until the
dispensing port 340 and the opening 342 align, as shown in FIG.
17C. At this point, the paddle 160 rotates to churn the contents of
the pod in a downward direction out the dispensing port 340.
[0135] FIGS. 17D and 17E show first end 210 of the pod without the
cap 336. FIG. 17D shows the foil seal 338 covering the dispensing
port 340. FIG. 17E is a perspective view of the first end 210
without the foil seal 338. The foil seal 338 seals the liquid,
semi-solid, and/or solid contents of the pod during sterilization,
transit, and storage. The diameter of the dispensing port 340 is
about 5/8 of an inch. Some dispensing ports are other sizes (e.g.,
0.2 to 1 inches in diameter).
[0136] FIGS. 18A-18D are perspective views of the first end 210 of
a pod with a rotatable cap 350. FIGS. 18B-18D are perspective views
of the cap 350 shown in FIG. 18A. In these figures, the cap 350 is
illustrated as being transparent to make it easier to describe the
inner components are visible. Typically, caps are opaque.
[0137] The cap 350 is attached to the first end 210 of the pod
using a rivet 352. The cap 350 covers the first end 210 of the pod
and a foil seal 338 initially disposed covering the dispensing port
340 of the pod.
[0138] FIG. 18B shows a top perspective view of the cap 350 with a
knife-edge 356, a nozzle 358, and a support plate 360. The
knife-edge 356, support plate 360, and nozzle 358 are rotatably
coupled to the cap 350 and move between a closed position to a
dispensing position. The closed position of the cap 350 is shown in
FIGS. 18A and 18B. The dispensing position is shown in FIG. 18C. In
the closed position, the support plate 360 covers the dispensing
port 340 and the foil seal. In the dispensing position, the nozzle
358 aligns with the dispensing port 340 and the foil seal 338 is
disposed on an upper surface of the knife-edge 356.
[0139] The cap 350 rotates to move the nozzle 358, knife-edge 356,
and support plate 360 from the initial position to the dispensing
position. As the plate rotates, the knife scrapes the foil seal and
removes the foil seal from its position covering the dispensing
port 340. The cap 350 continues to rotate and the knife-edge 356
covers the dispensing port. The seal 338 moves up the knife-edge
356, guided by the support plate 360 and engages the knife-edge
356, as shown in FIG. 18D. The cap 350 rotates further and the
nozzle 358 aligns with the dispensing port 340. The paddle 160
rotates in a direction that churns the contents of the pod downward
towards the dispensing port 340. The support plate 360 serves
strengthens and supports to the overall first end 210 during the
sterilization process (e.g., retort or HPP) when internal and
external pressures may otherwise cause the end to be
compromised.
[0140] FIGS. 19A and 19B show a cap 389 including plate 390 and a
slider 392. The cap 389 is rotatably connected to the first end 210
of a pod. The slider 392 is disposed between the plate 390 and the
first end 210 of the pod. A hinge 396 fastens a first end 398 of
the slider 392 to the first end 210 of the pod. A boss 400 extends
from a second end 402 of the slider 392. The plate 390 defines an
aperture 403, an arced guide track 404, and a linear guide track
406. The arced guide track 404 engages the hinge 396 of the first
end 210 of the pod 150. The linear guide track 406 engages the boss
400 of the slider 392.
[0141] FIG. 19A shows the plate 390 and the slider 392 in an open
position in which the aperture 403 is aligned and in fluid
connection with the dispensing port 340. In the open position, the
boss 400 is at a first end 408 of the linear guide track 406 and
the hinge 396 is at a first end 410 of the arced guide track 404.
In the closed position, the second end 402 of the slider 392 covers
the dispensing port 340. The hinge 396 abuts a second end 412 of
the arced guide track 404 and the boss 400 abuts a second end 414
of the linear guide track 406.
[0142] To move from the open position to the closed position, the
plate 390 is rotated counterclockwise. The hinge 396 follows the
arced guide track 404 from the first end 410 to the second end 412.
The boss 400 also moves along the linear guide track 406 from the
first end 408 to the second end 414. The rotation of the plate 390
moves the second end 402 of the slider 392 to cover the dispensing
port 340. When the hinge 396 is at the second end 412 of the arced
guide track 404, the slider 392 fully covers the dispensing port
340.
[0143] To move from the closed position to the open position, the
plate 390 is rotated clockwise. The hinge 396 follows the arced
guide track 404 from the second end 412 to the first end 410. The
boss 400 also moves along the linear guide track 406 from the
second end 414 to the first end 408. The clockwise rotation of the
plate 390 moves the second end 402 of the slider 392 to expose the
dispensing port 340. When the hinge 396 is at the first end 410 of
the arced guide track 404, the aperture 403 is aligned and in fluid
communication with the dispensing port 340, as shown in FIG.
19A.
[0144] FIGS. 20A and 20B are views of a plate 420 disposed on the
first end 210 of a pod. The plate defines an aperture 422 and an
arced guide track 424. The slider 392 is disposed between the plate
420 and the first end 210 of the pod 150. A link arm 426 is
disposed between the slider 392 and the plate 420. As described
with reference to FIG. 19A, the slider 392 is connected to the
first end 210 of the pod 150 by the hinge 396. The boss 400 extends
from the slider 392 and acts as a hinge, rotatably and
translationally connecting the second end 402 of the slider 392 to
the link arm 426. The link arm 426 includes a projection 427 that
acts as a hinge, rotationally and translationally connecting the
plate 420 and the link arm 426.
[0145] FIG. 20A shows the plate 420, slider 392, and link arm 426
in the closed position. The second end 402 of the slider 392 covers
the dispensing port 340. FIG. 20B shows the plate 420 in the open
position, in which the aperture 422 is aligned and fluidly
connected with the dispensing port 340.
[0146] The plate 420 operates similarly to plate 390. In the open
position, the hinge 396 is positioned at a first end 428 of the
arced guide track 424. In the closed position, the hinge 396 is
positioned at a second end 430 of the arced guide track 424. The
plate 420 rotates to move the arced guide track 424 relative to the
hinge 396.
[0147] To move from the closed position, shown in FIG. 20A, to the
open position, shown in FIG. 20B, the plate 420 rotates clockwise.
The projection 427 rotates with the plate 420 and pulls the link
arm 426 clockwise. The boss 400 that connects the link arm 426 to
the slider 392 pulls the second end 402 of the slider 392
clockwise, exposing the dispensing port 340. The aperture 422
rotates clockwise to align with the dispensing port 340. When the
hinge 396 abuts the first end 428 of the arced guide track 424, the
aperture 422 is aligned with the dispensing port 340.
[0148] To move from the open position, shown in FIG. 20B, to the
closed position, shown in FIG. 20A, the plate 420 rotates
counterclockwise. The projection 427 rotates with the plate 420 and
pushes the link arm 426 counterclockwise. The boss 400 that
connects the link arm 426 to the slider 392 pushes the second end
402 of the slider 392 counterclockwise, covering the dispensing
port 340 with the second end 402 of the slider 392. The aperture
422 rotates counterclockwise moving out of alignment with the
dispensing port 340. When the hinge 396 abuts the second end 430 of
the arced guide track 424, the second end 402 of the slider 392
covers the dispensing port 340.
[0149] FIG. 21A is a perspective view of a pod 150 with the first
end 210 connected to a cap 432 and a slider 434 disposed between
the pod 150 and the cap 432. The slider 434 has a flat portion 436
and a plug portion 438. The plug portion 438 plugs the dispensing
port 340 in the closed position. The cap 432 defines an aperture
440 that aligns with the dispensing port 340 in the open
position.
[0150] FIGS. 21B and 21C are exploded views of the pod 150, cap
432, and slider 434 aligned to be in the closed position. The cap
432 includes a recess 442 that holds the slider 434. The cap 432
and slider 434 are attached to the second end first end 210 of the
pod 150 using a bolt 444. The slider 434 and cap 432 are rotatable
relative to each other and relative to the bolt 444.
[0151] FIGS. 21D and 21E show the closed position with the plug
portion 438 of the slider 434 in the dispensing port 340. The cap
432 is shown apart from the pod 150 for ease of viewing.
[0152] FIGS. 21F and 21G show an exploded view and a bottom view of
the cap 432 and slider 434 in the open position. The cap 432
rotates to move the slider 434 between the open and closed
position. As the cap 432 continues to rotate, the slider 434 tucks
into the recess 442 of the cap 432, the sliding plug 438 is removed
from the dispensing port 340, and the aperture 440 of the cap 432
aligns with the dispensing port 340. This configuration can be
reversed into the closed position by rotating the cap 432 in the
opposite direction, sliding plug 438 up and into the dispensing
port 340 to reseal it.
[0153] FIGS. 22A and 22B are schematic views of a pod 150 engaged
with a gear wheel 450. The gear wheel 452 engages a plate or cap
(e.g., the plates of FIG. 17A, 18A, 19A, 20A, or the cap of FIG.
21A) of the pod 150 when the pod 150 is inserted into a machine.
The gear wheel 452 is attached to a motor (not shown) that drives
the gear wheel 452. Rotation of the gear wheel 452 rotates the
plate or cap of the pod 150. When it is time to dispense cooled
food or drink from the pod 150, the motor is activated to rotate
the gear wheel to rotate the plate or cap and open the cover of the
pod 150 to dispense its contents.
[0154] When the pod 150 is inserted into the evaporator 108 of the
machine 100 a plate or cap attached to the first end 210 of the pod
rests against the gear wheel 452. In some rotators, the gear wheel
is shaped as a circular donut or a roller. To dispense cooled food
or drink, the motor 454 is activated by a controller and rotates
the gear wheel 452 via the rod 456. The gear wheel 452 engages the
plate or cap, moving the plate or cap into the open position from
the closed position. By reversing the motor 454, the gear wheel 452
can moving the plate or cap into the closed position from the open
position. Some gear wheels can be activated manually by the machine
user.
[0155] FIGS. 23A and 23B are schematic views of a pod 150 engaged
with a gear wheel 452. The gear wheel 452 that engages a plate or
cap and is coupled to a motor 454 that drives the gear wheel 452
via a rod 456. Rotation of the gear wheel 452 rotates the plate or
cap of the pod 150. When it is time to dispense cooled food or
drink from the pod 150, the motor is activated to rotate the gear
wheel to rotate the plate or cap and open the cover of the pod 150
to dispense its contents.
[0156] FIGS. 24A and 24B are perspective views of a removable lid
464 that covers an end of a pod 150. The removable lid 462 is
integrally formed with the pod 150 and has an edge 465 that defines
a weakened area of aluminum where the removable lid 462 meets the
first neck 216. The removable lid 462 further includes a tab 466
with a puncturing surface 468, aligned with the edge 465 and a ring
470 on the side opposite the puncturing surface 468. The removable
lid 462 is removed by lifting the ring 470 thereby pressing the
puncturing surface 468 into the weakened area. The puncturing
surface 468 punctures the weakened area and the user pulls the
removable lid 462 away from the pod 150 using the ring 470. The
removable lid 462 covers the dispensing assembly. The removable lid
462 helps maintain the integrity of the pod during the
sterilization process and helps the pod 150 maintain sterility of
its contents following the sterilization process.
[0157] The weakened section is produced in manufacturing by scoring
the edge 465 of the removable lid 464. The edge 465 may be created
by a laser or stamping with a punch and die. In some embodiments,
the weakened section is a section that is thinner than the walls of
the pod. In some embodiments, the removable lid is adhesively
attached or mechanically attached to the pod. The dispensing
assembly may be any of the configurations described with respect to
FIGS. 17A-21G.
[0158] FIGS. 25A-25C are a perspective, a cross-sectional, and a
top-down view of a pod-machine interface 480 with an evaporator 108
as described with respect to FIG. 15A. The pod-machine interface
480 has a bore 486 for hingably attaching the pod-machine interface
480 to the body of a machine for rapidly cooling food or drinks.
The drive shaft 126 is the only component of the machine 100
shown.
[0159] The evaporator 108 is in its closed position holding the pod
150. The drive shaft 126 engages with the pod 150 to rotate the
mixing paddle 486. The mixing paddle 486 is a three-blade paddle
with blades that have large openings adjacent a stem 488 of the
paddle 486. The angle of inclination of the blades 490 relative to
a plane extending along an axis of pod 484 varies with distance
from the end of the pod 150. The outer edges of the blades 490
define slots that can receive a rim of the pod 484 during
assembly.
[0160] The pod-machine interface 480 includes a housing 491 with a
ledge 492 and a wall 494 that extends upward from the ledge 492.
The ledge 492 and the wall 494 guide and support refrigerant fluid
lines (not shown) attached to the evaporator 108. The fluid lines
extend from a recess 496 that is defined in the wall 494 to the
first fluid inlet port 312 and the second fluid outlet port 318 of
the evaporator 108 on the side of the evaporator 108 opposite the
recess 496. The evaporator 108 has two inlet ports and two outlet
ports because the first portion 128 of the evaporator 108 and the
second portion 130 of the evaporator 108 define two separate flow
paths.
[0161] The evaporator 108 is disposed in the pod-machine interface
480 such that an annular space 495 is defined between the outer
wall of the evaporator 108 and the inner wall of the casing of the
pod-machine interface 480. The annular space 495 is filled with an
insulating material to reduce heat exchange between the environment
and the evaporator 108. In the pod-machine interface 480, the
annular space 495 is filled with an aerogel (not shown). Some
machines use other insulating material, for example, an annulus
(such as an airspace), insulating foams made of various polymers,
or fiberglass wool.
[0162] FIGS. 26A and 26B are perspective views of a pod 502. The
pod 502 is substantially similar to the pod 150 shown in FIGS. 6A
and 7A. However, the pod 502 includes a plug 504 that engages the
drive shaft 126 of the machine 100 and facilitates the flow of gas
into the pod 502 during either the manufacturing process or during
the cooling process in the machine. Gas (for example, nitrogen,
nitrous oxide, carbon dioxide, argon, or a combination of these
gases) can injected into the pod 502 through the plug 504 during
manufacturing. Typical pressure that the pod experiences during the
retort sterilization process is between 20-100 psi. The plug 504
pops out of the pod 502 if the internal pressure exceeds 100 psi.
To prepare the pod 502 for the plug 504, the second end 212 of the
pod 502 is deep drawn (e.g., by stretching or forming the base dome
of the can during manufacturing while also punching or drawing the
hole out of the center with the forming dies) during manufacturing
of the pod 502.
[0163] The plug 504 defines a central opening or recess 506 that
receives the drive shaft from the lid 112 of the machine 100. The
recess 506 is shaped to rotationally lock the grommet to the drive
shaft 126. The plug 504 has flat surfaces that mate with the
central opening or recess of the mixing paddle (not shown). The
central opening or recess has the same flat surface configuration.
The plug 504 rotates relative to the pod 502 when the motor and the
drive shaft 126 engage the plug 504. In some grommets, the drive
shaft penetrates the grommet to engage the paddle. The plug 504
accepts the drive shaft and engages the mixing paddle. Gas can be
injected into the pod 150 through the grommet to maintaining
pressure in the pod 150 during the refrigeration cycle and control
the texture of the contents of the pod during the refrigeration
cycle.
[0164] A variety of mixing paddles can be used with the pods
described in this specification. The mixing paddles described with
respect to the following figures can be used in any of the pods
described in this specification. Generally, the mouth of the pod is
smaller than the major diameter of the pod. The internal mixing
paddle needs to be either flexible to squeeze smaller for entry
thru the mouth of the can and expand large once in the can to be
able to scrape the wall or the blades need to be slotted. In some
cases, the blades of mixing paddles give rigidity to the thin wall
pod during packaging and shipping and give outward structure to the
pod when a clamshell evaporator closes against it.
[0165] FIG. 27 is a perspective view of a mixing paddle 510 with
three blades 512 that extend along the length of a central stem
514. The blades 512 define large openings 516 through which the
contents of the pod 150 flow during mixing. The paddle 510 also
includes a projection 518 that extends out of the second end 212 of
the pod 150. As the second end 212 of the pod 150 is concave, the
projection 518 is shorter than an upper lip of the pod 150. In some
embodiments, the projection mates with a female drive shaft
inserted into the pod rather than projecting out of the pod.
[0166] FIG. 28 is a perspective view of a mixing paddle 520 with
three blades 522 that wind along the length of a central stem 524
at a pitch that varies with distance along an axis of the paddle.
The blades 522 define large openings 525 that extend from a first
end 526 of the blade 522 to a second end 528 of the blade 522. The
pitch of the blades increases with distance from the first end 526
of the pod 150. The portions of the blades 522 with a shallow pitch
remove frozen confection that otherwise would build up on the inner
surface of the walls of the pod 150 during freezing. The portions
of the blades 522 with a steeper pitch churn the frozen confection
while lifting the frozen confection from the floor of the pod 150.
The portions of the blades 522 with a steep pitch also presses the
frozen confection out of the end 210 of the pod when rotated in the
opposite direction and the first end 210 of the pod 150 is
opened.
[0167] FIG. 29A is a perspective view of a mixing paddle 486. The
paddle 486 has three helical blades 490 that have large openings
532 adjacent a stem 488 of the paddle 486. The angle of inclination
of the blades 490 relative to a plane extending along an axis of
pod 484 varies with distance from the end of the paddle. The outer
edges of the blades 490 define slots 534 that can receive a rim of
the pod 484 during assembly. The slots 534 extend into the blades
490 which produces a flexible blade 490. A flexible blade is
beneficial during assembly of the pod as the neck of the pod is
generally smaller in diameter than the diameter of the paddles.
[0168] FIG. 29B is a schematic view illustrating insertion of the
mixing paddle 486 into a pod 150. The slots 532 act as threads
during manufacturing and allow a paddle with a wider diameter than
the first neck 216 to enter the pod 150. As previously described
with reference to FIGS. 6A and 6B, the pod 150 has a wider barrel
220 than mouth. The width of the paddle 486 touches or almost
touches the sides of the barrel 220 to remove built up or frozen
ingredients.
[0169] FIG. 30A is a perspective view of a mixing paddle 540 that
has three helical blades 542. A first end 454 of the blades 542
connect to a first unit 556 and the second end 548 of the blades
542 connect to a second unit 558. The first unit 546 and the second
unit 550 have key-shaped openings that receive a central rod that
is shaped to fit the openings. When the rod is received by the
openings, the paddle 540 is rotationally coupled to the rod.
[0170] The paddle 540 is flexible and made of resilient material.
The paddle 540 can be twisted clockwise to reduce the diameter of
the paddle 540. The paddle 540 can be twisted counterclockwise to
increase the diameter of the paddle 540. The paddle returns to the
original diameter when the twisting force is removed. The diameter
of the paddle 540 is typically larger than the diameter of the
upper end DUE of the pod 150.
[0171] FIG. 30B is a schematic view illustrating insertion of the
mixing paddle 540 and a complimentary rod 652 into a pod. The
paddle 540 is also a flexible and resilient paddle 540. The paddle
540 is manipulated to fit though the second neck 218 and the rod
652 is then inserted through the second neck 218 and the openings
552, 554. Inserting the rod 652 through the openings 552, 554
causes blades to expand and sit flush with pod walls. The rod 652
abuts the first end 210 of the pod 150. A recess 653 is defined in
the end of the rod 652 that abuts the first end 210. The recess 653
is sized to receive and rotationally couple to the drive shaft
126.
[0172] FIG. 31 is a perspective view of a mixing paddle 560 that
has three helical blades 562 that extend along the length of a
central stem 564. Each blade 566 defines an upper opening 566 and a
lower opening 568. The blades 562 increase in pitch as the blade
562 extends from an upper end 570 of the paddle 560 to a lower end
572 of the paddle 560. The blades 562 have protrusions 574 on edges
of the blades 562. The protrusions 574 alternate to remove built up
ingredients from the interior of the pod 150. The protrusions 574
are arranged such that the entire surface area of the barrel 220 is
wiped or cleaned by the protrusions 574 of the three blades
562.
[0173] FIG. 32A is a perspective view of a mixing paddle 578 that
has two helical blades 580 that extend along the length of the
central stem 581. The paddle 578 is substantially similar to the
paddle 560. However, the paddle 578 has two blades rather than
three blades 562. The blades 580 includes alternating notches 582
that cover the entire interior surface area of the barrel of the
pod 150. The notches 582 perpendicularly project from edges of the
blades 580. In some mixing paddles, the outer diameter of the
mixing paddle is narrower at one end to increase the ease of
insertion into the pod during assembly and to maintain the paddle
is a concentric position within the pod during the refrigeration
cycle.
[0174] FIGS. 32B and 32C are schematic views illustrating insertion
of the mixing paddle 578 into a pod. The paddle 578 is worked into
the pod 150 by wiggling the paddle 578 though the first neck 216 or
by rotating the paddle through the first neck 216. FIG. 30B shows
the paddle 578 fully inserted into the pod 150. The plate 390 is
attached to the first end 210 of the pod 150.
[0175] FIG. 33 is a perspective view of a mixing paddle 584 that
has two helical blades 586 that extend along the length of the
central stem 588. The paddle 584 is substantially similar to paddle
578. However, paddle 584 has angled notches 589 and angled notches
582. These notches help to facilitate the insertion of the paddle
584 into the pod without catching on a cornered notch.
[0176] In some mixing paddles, components are stamped in two or
more pieces from flat aluminum sheet and fixably nested to achieve
a mixing paddle with a central stem with mixing blades. Some mixing
paddles are first stamped and then welded to produce a central
stem.
[0177] FIG. 34A is a perspective view of a mixing paddle 590 that
has two helical blades 592 that extend along the length of a
central stem 594. The paddle 590 is otherwise substantially similar
to the paddle 578. The paddle 578 can be formed from a single piece
of sheet metal. The central stem is a stamped recess 596 for
receiving the drive shaft 126.
[0178] FIGS. 34B-34D are schematic views illustrating insertion of
the mixing paddle 590 into a pod. The blades 592 are notched to
help insertion into a pod 150 through the first neck 216. The
blades 592 have alternating notches. This allows the paddle 578 to
pass through the first neck 216 during manufacturing and maintain
contact with the inner wall of the barrel 220. Some paddles 578 do
not contact the inner wall of the barrel, but are sufficiently
close to the inner wall of the barrel 220 to remove the ingredients
of the pod that freeze and stick to the inner wall of the barrel
220. The paddle may be, for example, 5-500 microns away from the
inner wall of the barrel 220.
[0179] FIG. 35 is a perspective view of a mixing paddle 600 that
includes two helical blades 602 that extend along a central axis
604. The helical blades 602 have a uniform pitch. The paddle 600 is
substantially similar to paddle 510, shown in FIG. 28A. However,
paddle 600 is integrally formed with the second end 210 of the pod
150. Paddle 600 has a smooth blade without notches. A projection
518 extends from the main stem of the paddle 510. Some paddles have
a central opening or recess to receive the drive shaft 126 of the
machine.
[0180] FIG. 36A is a perspective view of a mixing paddle 606 that
has three helical blades 608. A first end 610 of the blades 608
connect to a first unit 612 and the second end 614 of the blades
608 connect to a second unit 616. The first unit 612 and the second
unit 616 have key-shaped openings 620, 622. The key-shaped openings
620, 622 receive a central rod (not shown) that is shaped to fit
the openings 620, 622. When the rod is received by the openings
620, 622, the paddle 606 is rotationally coupled to the rod.
[0181] The paddle 606 is flexible and is made of resilient
material. The paddle 606 can twist clockwise to reduce the diameter
of the paddle 606. The paddle 606 can be twisted counterclockwise
to increase the diameter of the paddle 606. The paddle returns to
the original diameter when the twisting force is removed. The
diameter of the paddle 606 is approximately larger than the
diameter of the upper end D.sub.UE of the pod 150 and smaller than
the diameter of the barrel D.sub.B of the pod 150.
[0182] In some paddles, the diameter of the central rod is larger
than the diameter of the openings. Openings are made of either a
resilient material and/or designed to expand when the central rod
is inserted into the openings. When the central rod is inserted
into the openings, the diameter of the paddle increases.
[0183] FIGS. 36B-36D are schematic views illustrating insertion of
the mixing paddle 606 into a pod. The openings 620, 622 are sized
to receive the complimentary rod 650. The rod 650 and the openings
620, 622 are shaped so that when the rod 650 engages the openings
622, 620 the rod 650 and paddle 606 are rotationally coupled. In
FIG. 36A, both the rod 650 and the paddle 606 are outside the pod
150. The paddle 606 is first inserted into the first end 210 of the
pod 105. The paddle is flexible and can be manipulated (e.g.
twisted or compressed) to fit through the second neck 218. Once the
paddle 606 is inside the interior of the pod 150, as shown in FIG.
36B, the rod 650 is inserted through the opening 620, 622. FIG. 36C
shows the paddle 606 and rod 650 within the interior of the pod.
The rod 650 abuts the first end 210 of the pod 150. A recess 651 is
defined in the end of the rod 650 that abuts the first end 210. The
recess 651 is sized to receive and rotationally couple to the drive
shaft 126.
[0184] FIG. 37A is a perspective view of a mixing paddle 626 that
includes three helical blades 628 that attach on a first end 630 to
a central stem 632. A second end 634 of the blades 628 is free. The
second ends 634 of the blades 628 are is easily compressed when the
free ends of transverse mechanical forces are applied to the second
ends 634 during manufacturing.
[0185] FIG. 37B is a schematic view illustrating insertion of the
mixing paddle 626 into a pod. To insert the paddle 626, the second
end 634 blades 628 are pressed towards the central stem 632. The
paddle 626 is inserted into the second neck 218 of the pod 150.
Once in the pod 150, the blades 628 are released and return to
their original diameter, which is equal to or slightly smaller than
the diameter of the barrel D.sub.B.
[0186] FIG. 38 is a perspective view of a mixing paddle 636 that
includes four bowed blades 638 that connect first end 642 to a
first hub 644 and at a second end 646 to a second hub 648. The
blades 638 are made of a resilient material deforms when force is
applied to the top and bottom of the paddle. The bow of the blades
638 can increase when the ends of the paddle are pressed together.
In the undeployed position, the blades 638 are slightly bowed. In
the deployed position, the blades 638 bow out. The paddle 636 is
inserted into the pod 150 in the undeployed position. When the
paddle 636 is in the interior of the pod 150, a compressive force
is applied to the first hub 644 of the paddle 363 and the blades
638 bow outwards. Some paddles include a lock that prevent the
paddle from returning to the undeployed configuration. In some
paddles, the compressive force permanently deforms the blades 638
into the deployed position.
[0187] FIG. 39 is a perspective view of a mixing paddle 633 with a
head 635 that extends to sidewalls of the pod. The head 635 is
disc-shaped and helps maintains the paddle 633 in concentric
position with the pod. The paddle 633 is substantially similar to
paddle 600 shown in FIG. 281 but has a female connection 637 rather
than a male protrusion. A driveshaft of a machine receiving the pod
is inserted into the female connection 637 during use. The head 635
rotates as blades 639 rotate to churn the contents of the pod. This
configuration increases the likelihood that the driveshaft remains
sterile and does not contact the contents of the pod.
[0188] FIG. 40 is a perspective view of a mixing paddle 655 that
has two helical blades 657 that extend along the length of a
central stem. The paddle 655 can be formed from a single piece of
sheet metal. The central stem is a stamped recess 661 for receiving
the drive shaft 126. The stamped recess 661 has an upper section
663 and a lower section 665 that are stamped in a first direction.
The stamped recess also has a middle section 667 that is stamped in
a second direction, opposite the first direction. The stamping
approach can provide reduced manufacturing costs relative to
welding-based approaches.
[0189] FIG. 41 is a perspective view of a mixing paddle 675 in the
pod 150. The paddle 675 has a central stem 677 and a blade 679 that
extends from the stem 677. The blade 679 has openings 681 and a
notch 683 at a dispensing end 685 of the blade 679. When the paddle
675 rotates to mix the contents of the pod 150, the notch 783
scoops the contents of the pod from the bottom and prevents the
contents at the bottom of the pod 150 freezing into ice.
[0190] A custom "filling head" is used to mate with, or altogether
avoid, the mixing paddles during the filling process. This approach
allows the filling head to enter into the pod and dispense liquid
contents into the pod without splash up. Additionally, to account
for the additional volume required for the confectionery overrun,
there is more "headspace" (i.e., open space) left at the top of the
pod then with a traditionally filled can. The filling process is
adapted for this additional headspace during pressurization
process.
[0191] FIGS. 42A and 42B illustrate an approach to filling a pod
150 with ingredients. The manufacturing machinery 664 includes a
spout 666 that has a first head 668, a second head 670, and a third
head 672. The heads 668, 670, 672 are sized to fit between the
blades 230 of the paddle. FIG. 36A shows the spout 666 engaged with
the pod 150. The heads 668, 670, 672 flow liquid ingredients into
the pod 150. The spout 666 is a reversed funnel that fills the pods
without being inserted into the pod. Once the spout 666 is removed
from the first neck 216 of the pod 150, the pod 150 closed. The pod
150 is sterilized with ingredients 674 in the interior of the pod
150. Some pods are filled using a counter pressure filling system
using a hose.
[0192] Some pods can be recycled. For example, some pods have a
fully removable can end. After the freezing cycle is complete, the
user removes the pod from the machine, removes the entire can end
(can end includes the sub-component exit port mechanism), removes
the plastic mixing paddle from the pod, and separates the plastic
and metal components for easy recyclability.
[0193] FIGS. 43A and 43B shows a pod with a removable internal
paddle 680. The removable paddle 680 is substantially similar to
the paddle 626 shown in FIG. 37A. However, the removable paddle 680
is removable from the pod 150. The user removes a lid 682 of the
second end 212 of the pod 150. The lid 682 can be removed, for
example by the techniques and configuration shown in FIGS. 43A and
43B. Opening the first end 210 of the pod 150 exposes the removable
paddle 680. The user then grabs the paddle 680 by a first end 684
of the paddle 680. A second end 686 of the paddle 680 compresses to
exit through the second neck 218. The paddle can be reused in a
different pod or reused within the same pod.
[0194] FIGS. 44A and 44B show a pod with an upper casing 690 for
storing toppings 692. The upper casing 690 includes a first opening
694 and a second opening 696 that provides a conduit between the
interior of the pod 150 and an interior 698 of the casing 690. A
rotatable plate 700 covers the openings 694, 696 and prevents the
toppings 692 from mixing with the contents of the pod 150. In the
final stages of freezing, for example 10 second prior to
dispensing, the plate 700 is rotated and a first aperture 702 of
the plate 700 aligns with the first opening 694. A second aperture
704 of the plate 700 aligns with the second opening 696. The
toppings 692 fall into and are mixed with the contents of the pod
150 and are dispensed with the contents of the pod 150. FIG. 38A
shows chocolate chips as a topping. Some other toppings includes
sprinkles, cookie crumps, syrups, jellies, fruit pieces, freeze
dried fruit pieces, batters, creams, or small or crushed candies.
The plate 700 can be coupled to the driveshaft extending from the
lid such that the plate rotates to its open position when the
driveshaft starts to rotate the mixing paddle.
[0195] FIGS. 45A and 45B show a gas-releasing disk 710 housed,
respectively, in a paddle and in a pod. FIG. 45A shows the paddle
510 of FIG. 28A having a hollow central stem 712. The central stem
712 is made of a gas permeable material. The gas-releasing disk 710
releases gas when the pod 150 is opened. Opening the pod 150
releases pressurized gas initially stored in the pod 150.
Depressurizing the pod 150 generates a pressure difference. The gas
from the gas-releasing disk 710 flows out of the disk and into the
contents of the pod 150 due to the pressure difference. FIG. 45B
shows a pod 150 the gas-releasing disk 710 disposed at the first
end 210 of the pod 150.
[0196] In both configurations, the gas-releasing disk 710 slowly
releases a gas into the ingredients of the pod 150 while the paddle
510 rotates and the evaporator 108 chills the ingredients. Slowly
releasing gas into the ingredients while freezing creates a
beverage or food product with velvety, lofty, smooth texture with
desirable overrun. The gas-releasing disk 710 may release nitrogen,
nitrous oxide, carbon dioxide, argon, or a combination of these
gases.
[0197] In some machines, nitrogen, nitrous oxide, argon or a
combination of these gases are pumped into the pod via the drive
shaft and/or mixing paddle during the refrigeration process. A
portion of this gas (e.g., nitrogen) may be diverted to
refrigeration system of the machine (e.g., the evaporator) to for
chilling and/or freezing purposes.
[0198] FIGS. 46A, 46B, and 46C are, respectively, a perspective
cutaway view, a side view, and an exploded view of a stack 720 of
bases 162 during manufacturing. The base 162 is previously
described with reference to FIG. 8. The base 162 includes an outer
shelf 722, an inner shelf 724, a circumferential valley 726, the
protrusion 165, and a flat area 728. The base 162 is proportioned
so that when stacking, the outer shelf 722 of a base 162 abuts the
outer shelf 722 of a different base 162 and the inner shelf 724 of
the base 162 abuts the inner shelf 724 of another base 162. The
protrusion 165 is a height H.sub.A from the flat portion 128.
H.sub.B is the height between the flat area 728 of a base 162 and
the flat are 128 of another base 162 stacked on the initial base
162. The height H.sub.A is equal to or smaller than the height
H.sub.B. This configuration help prevent the stack 720 of bases 162
from leaning or tilting during manufacturing. The stack of bases
162 are used in a manufacturing line to close the open ends of can
bodies after the can bodies have been filled.
[0199] The pods and accompanied components described in this
specification may be made to be either single-use disposable system
or reusable systems.
[0200] A number of embodiments of these systems and methods have
been described. Nevertheless, it will be understood that various
modifications may be made without departing from the spirit and
scope of this disclosure. Accordingly, other embodiments are within
the scope of the following claims.
* * * * *