U.S. patent application number 17/083104 was filed with the patent office on 2021-04-15 for food preparation devices, systems, and methods.
This patent application is currently assigned to ZimplyFresh, LLC. The applicant listed for this patent is ZimplyFresh, LLC. Invention is credited to Manju Karthikeyan, Narayan Tripunithura Mahadeva, Malavika Mantry.
Application Number | 20210106041 17/083104 |
Document ID | / |
Family ID | 1000005303259 |
Filed Date | 2021-04-15 |
View All Diagrams
United States Patent
Application |
20210106041 |
Kind Code |
A1 |
Mantry; Malavika ; et
al. |
April 15, 2021 |
FOOD PREPARATION DEVICES, SYSTEMS, AND METHODS
Abstract
A food preparation device is disclosed. The food preparation
device can include an ingredient combining apparatus to introduce a
fluid food ingredient and a solid food ingredient to one another
within a package. The food preparation device can also include a
mixing apparatus to mix the fluid food ingredient and the solid
food ingredient to form a food mixture in the package. In addition,
the food preparation device can include a forming apparatus to form
the food mixture into a predetermined shape within the package.
Inventors: |
Mantry; Malavika; (Mason,
OH) ; Karthikeyan; Manju; (Salt Lake City, UT)
; Mahadeva; Narayan Tripunithura; (Buffalo Grove,
IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ZimplyFresh, LLC |
Salt Lake City |
UT |
US |
|
|
Assignee: |
ZimplyFresh, LLC
Salt Lake City
UT
|
Family ID: |
1000005303259 |
Appl. No.: |
17/083104 |
Filed: |
October 28, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16209833 |
Dec 4, 2018 |
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17083104 |
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14837814 |
Aug 27, 2015 |
10143229 |
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16209833 |
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62042781 |
Aug 27, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A23P 30/00 20160801;
A23P 30/10 20160801 |
International
Class: |
A23P 30/00 20060101
A23P030/00; A23P 30/10 20060101 A23P030/10 |
Claims
1. A food preparation device, comprising: an ingredient combining
apparatus to introduce a fluid food ingredient and a solid food
ingredient to one another within a package; a mixing apparatus to
mix the fluid food ingredient and the solid food ingredient to form
a food mixture in the package; and a forming apparatus to form the
food mixture into a predetermined shape within the package.
2. The device of claim 1, wherein the ingredient combining
apparatus comprises a pressurized fluid source fluidly coupleable
to the package to provide pressurized fluid to one of the
compartments to break the frangible seal.
3. The device of claim 1, further comprising a package securing
mechanism to secure the package during operation of the food
preparation device.
4. The device of claim 3, wherein the package securing mechanism
comprises a fluid port configured to interface with the package to
fluidly couple the pressurized fluid source and the package.
5. The device of claim 3, wherein the package securing mechanism
comprises a clamp configured to engage a portion of the
package.
6. The device of claim 5, wherein at least a portion of the clamp
is movable to accommodate inflation of the package by a pressurized
fluid.
7. The device of claim 1, wherein the mixing apparatus comprises an
orbital shaker.
8. The device of claim 1, wherein the mixing apparatus further
comprises a package support to provide support for the package
while forming the food mixture.
9. The device of claim 1, wherein the forming apparatus comprises a
die to form the food mixture into the predetermined shape.
10. The device of claim 1, further comprising a heating apparatus
configured to heat at least one of the fluid food ingredient and
the solid food ingredient.
11. The device of claim 1, further comprising a drying apparatus to
remove moisture from the food mixture.
12. The device of claim 1, further comprising a housing disposed
about the ingredient combining apparatus, the mixing apparatus, and
the forming apparatus.
13. The device of claim 1, further comprising a receptacle within
the housing to receive the package, wherein at least one of the
mixing apparatus and the forming apparatus are operable on the
package when in the receptacle.
14. The device of claim 1, further comprising a topping dispenser
to apply a topping to the food mixture formed in the predetermined
shape.
15. A food preparation system, comprising: a package having a solid
food ingredient disposed therein; and a food preparation device,
having an ingredient combining apparatus to introduce a fluid food
ingredient and the solid food ingredient to one another within the
package, a mixing apparatus to mix the fluid food ingredient and
the solid food ingredient to form a food mixture in the package,
and a forming apparatus to form the food mixture into a
predetermined shape within the package.
16. The system of claim 15, wherein the solid food ingredient is
contained within the package by a frangible seal.
17. The system of claim 16, wherein the fluid food ingredient and
the solid food ingredient are disposed in the package in separate
compartments of the package formed at least in part by the
frangible seal.
18. The system of claim 17, wherein the ingredient combining
apparatus comprises a pressurized fluid source fluidly coupleable
to the package to provide pressurized fluid to one of the
compartments to break the frangible seal.
19. The system of claim 17, wherein the package is flexible.
20. The system of claim 17, wherein the package is disposable.
21-26. (canceled)
Description
PRIORITY DATA
[0001] This application is a continuation of U.S. patent
application Ser. No. 16/209,833, filed Dec. 4, 2018, which is a
continuation of U.S. patent application Ser. No. 14/837,814, filed
Aug. 27, 2015, now issued as U.S. Pat. No. 10,143,229, which claims
the benefit of U.S. Provisional Patent Application Ser. No.
62/042,781, filed on Aug. 27, 2014, each of which is incorporated
herein by reference.
BACKGROUND OF THE INVENTION
[0002] Food consumers often desire a nutritionally relevant snack
or meal to meet specific dietary requirements, such as a need for
immediate energy through carbohydrate, muscle mass and recovery
through protein, specific nutritional components (i.e., vitamins,
minerals, fiber, and whole grains, or delivering specific health
and lifestyle benefits including antioxidant or weight management
properties). In addition, consumers often crave a product that is
highly palatable due to its freshness, moistness, softness, and
warmth at consumption.
SUMMARY OF THE INVENTION
[0003] Although fresh, moist, warm foods are desirable to consume,
such foods are not typically available without significant
pre-work, preparation (e.g., ingredient selection, and weighing),
and manufacture (e.g., heating, cooling, mixing, and
shaping/molding) in the home or other location. A warm, moist,
fresh tasting snack is currently not believed to be available in a
convenient, single serve form while also providing and meeting
nutritional and lifestyle needs.
[0004] In one invention embodiment, a food preparation device is
provided. In some embodiments, the food preparation device can
include an ingredient combining apparatus to introduce a fluid food
ingredient and a solid food ingredient to one another within a
package. The food preparation device can also include a mixing
apparatus to mix the fluid food ingredient and the solid food
ingredient to form a (more or less homogeneous or non-homogeneous)
food mixture in the package. In addition, the food preparation
device can include a forming apparatus to form the food mixture
into a predetermined shape within the package.
[0005] Additional invention embodiments encompass a food
preparation system. In some aspects, such a system can include a
package having a solid food ingredient disposed therein.
Additionally, such a system can include a food preparation device
as recited herein, for example, that includes an ingredient
combining apparatus to introduce a fluid food ingredient and the
solid food ingredient to one another within the package. The food
preparation device can also include a mixing apparatus to mix the
fluid food ingredient and the solid food ingredient to form a food
mixture in the package. In addition, the food preparation device
can include a forming apparatus to form the food mixture into a
predetermined shape within the package.
[0006] Yet additional invention embodiments encompass methods for
preparing a food product. The method can include obtaining a
package having a solid food ingredient disposed therein. The method
can also include introducing a fluid food ingredient and the solid
food ingredient to one another within the package. The method can
further include mixing the fluid food ingredient and the solid food
ingredient to form a food mixture in the package. Additionally, the
method can include forming the food mixture into a predetermined
shape within the package. In some embodiments, the food may be
mixed and food product formed in a package without opening the
package (i.e. the package is unopened, or is substantially closed
and/or sealed).
[0007] There has thus been outlined, rather broadly, various
features of the invention so that the detailed description thereof
that follows may be better understood, and so that the present
contribution to the art may be better appreciated. Other features
of the present invention will become clearer from the following
detailed description of the invention, taken with the accompanying
claims, or may be learned by the practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The following detailed description of preferred embodiments
of the invention will be better understood when read in conjunction
with the appended drawings. For the purpose of illustrating the
invention, there are shown in the drawings embodiments which are
presently preferred. It should be understood, however, that the
invention is not limited to the precise arrangements and
instrumentalities of the embodiments shown in the drawings.
[0009] FIG. 1 is a schematic illustration of a food preparation
system, in accordance with an example of the present
disclosure.
[0010] FIG. 2 is a perspective view of a food preparation device,
in accordance with an example of the present disclosure.
[0011] FIGS. 3A and 3B are front views of the food preparation
device of FIG. 2.
[0012] FIG. 4 is a perspective view of a food preparation system,
in accordance with another example of the present disclosure.
[0013] FIG. 5 is a perspective view of the food preparation device
of FIG. 2 with a package on a package support in a forward position
prior to operation.
[0014] FIG. 6 is a perspective view of the food preparation device
of FIG. 2 illustrating operation of the device to secure a
package.
[0015] FIG. 7 is a perspective view of the food preparation device
of FIG. 2 illustrating a heating operation of the device.
[0016] FIG. 8 is a perspective view of the food preparation device
of FIG. 2 illustrating a rearward position of a package
support.
[0017] FIG. 9A is a side cross-sectional view of the food
preparation device of FIG. 2 illustrating a rearward position of a
package support and a fluid coupler disengaged from the package
support.
[0018] FIG. 9B is a side cross-sectional view of the food
preparation device of FIG. 2 illustrating a rearward position of a
package support and the fluid coupler engaged with the package
support.
[0019] FIG. 10 is a perspective view of the food preparation device
of FIG. 2 illustrating inflation of the package.
[0020] FIG. 11 is a front view of the food preparation device of
FIG. 2 illustrating inflation of the package.
[0021] FIG. 12 is a perspective view of the food preparation device
of FIG. 2 illustrating a mixing operation.
[0022] FIG. 13 is a perspective view of the food preparation device
of FIG. 2 illustrating a forming operation.
[0023] FIG. 14 is a front view of the food preparation device of
FIG. 2 illustrating a forming operation.
[0024] FIG. 15 is a perspective view of shaping dies of a food
preparation device that can be configured to form a plurality of
predetermined shapes, in accordance with an example of the present
disclosure.
[0025] FIG. 16 is a bottom view of a mixing apparatus of a food
preparation device, in accordance with an example of the present
disclosure.
[0026] FIG. 17 is a perspective view of a food preparation device,
in accordance with another example of the present disclosure.
[0027] FIG. 18A is a perspective view of a food preparation device,
in accordance with yet another example of the present
disclosure.
[0028] FIG. 18B is a front view of the food preparation device of
FIG. 18A.
[0029] FIG. 18C is a rear view of the food preparation device of
FIG. 18A.
[0030] FIG. 18D is a side view of the food preparation device of
FIG. 18A.
[0031] FIG. 18E is a side view of the food preparation device of
FIG. 18A.
[0032] FIG. 18F is a top view of the food preparation device of
FIG. 18A.
[0033] FIG. 18G is a bottom view of the food preparation device of
FIG. 18A.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0034] Although the following detailed description contains many
specifics for the purpose of illustration, a person of ordinary
skill in the art will appreciate that many variations and
alterations to the following details can be made and are considered
to be included herein. Accordingly, the following embodiments are
set forth without any loss of generality to, and without imposing
limitations upon, any claims set forth. It is also to be understood
that the terminology used herein is for the purpose of describing
particular embodiments only, and is not intended to be limiting.
Unless defined otherwise, all technical and scientific terms used
herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this disclosure belongs.
[0035] As used in this specification and the appended claims, the
singular forms "a," "an" and "the" include plural referents unless
the context clearly dictates otherwise. Thus, for example,
reference to "a sensor" includes a plurality of such sensors.
[0036] In this disclosure, "comprises," "comprising," "containing"
and "having" and the like can have the meaning ascribed to them in
U.S. Patent law and can mean "includes," "including," and the like,
and are generally interpreted to be open ended terms. The terms
"consisting of" or "consists of" are closed terms, and include only
the components, structures, steps, or the like specifically listed
in conjunction with such terms, as well as that which is in
accordance with U.S. Patent law. "Consisting essentially of" or
"consists essentially of" have the meaning generally ascribed to
them by U.S. Patent law. In particular, such terms are generally
closed terms, with the exception of allowing inclusion of
additional items, materials, components, steps, or elements, that
do not materially affect the basic and novel characteristics or
function of the item(s) used in connection therewith. For example,
trace elements present in a composition, but not affecting the
compositions nature or characteristics would be permissible if
present under the "consisting essentially of" language, even though
not expressly recited in a list of items following such
terminology. When using an open ended term, like "comprising" or
"including," it is understood that direct support should be
afforded also to "consisting essentially of" language as well as
"consisting of" language as if stated explicitly and vice
versa.
[0037] The terms "first," "second," "third," "fourth," and the like
in the description and in the claims, if any, are used for
distinguishing between similar elements and not necessarily for
describing a particular sequential or chronological order. It is to
be understood that any terms so used are interchangeable under
appropriate circumstances such that the embodiments described
herein are, for example, capable of operation in sequences other
than those illustrated or otherwise described herein. Similarly, if
a method is described herein as comprising a series of steps, the
order of such steps as presented herein is not necessarily the only
order in which such steps may be performed, and certain of the
stated steps may possibly be omitted and/or certain other steps not
described herein may possibly be added to the method.
[0038] The terms "left," "right," "front," "back," "top," "bottom,"
"over," "under," and the like in the description and in the claims,
if any, are used for descriptive purposes and not necessarily for
describing permanent relative positions. It is to be understood
that the terms so used are interchangeable under appropriate
circumstances such that the embodiments described herein are, for
example, capable of operation in other orientations than those
illustrated or otherwise described herein. The term "coupled," as
used herein, is defined as directly or indirectly connected in an
electrical or nonelectrical manner. Objects described herein as
being "adjacent to" each other may be in physical contact with each
other, in close proximity to each other, or in the same general
region or area as each other, as appropriate for the context in
which the phrase is used. Occurrences of the phrase "in one
embodiment," or "in one aspect," herein do not necessarily all
refer to the same embodiment or aspect.
[0039] As used herein, the term "substantially" refers to the
complete or nearly complete extent or degree of an action,
characteristic, property, state, structure, item, or result. For
example, an object that is "substantially" enclosed would mean that
the object is either completely enclosed or nearly completely
enclosed. The exact allowable degree of deviation from absolute
completeness may in some cases depend on the specific context.
However, generally speaking the nearness of completion will be so
as to have the same overall result as if absolute and total
completion were obtained. The use of "substantially" is equally
applicable when used in a negative connotation to refer to the
complete or near complete lack of an action, characteristic,
property, state, structure, item, or result. For example, a
composition that is "substantially free of" particles would either
completely lack particles, or so nearly completely lack particles
that the effect would be the same as if it completely lacked
particles. In other words, a composition that is "substantially
free of" an ingredient or element may still actually contain such
item as long as there is no measurable effect thereof.
[0040] As used herein, the term "about" is used to provide
flexibility to a numerical range endpoint by providing that a given
value may be "a little above" or "a little below" the endpoint.
Unless otherwise stated, use of the term "about" in accordance with
a specific number or numerical range should also be understood to
provide support for such numerical terms or range without the term
"about". For example, for the sake of convenience and brevity, a
numerical range of "about 50 angstroms to about 80 angstroms"
should also be understood to provide support for the range of "50
angstroms to 80 angstroms." Furthermore, it is to be understood
that in this specification support for actual numerical values is
provided even when the term "about" is used therewith. For example,
the recitation of "about" 30 should be construed as not only
providing support for values a little above and a little below 30,
but also for the actual numerical value of 30 as well.
[0041] As used herein, a plurality of items, structural elements,
compositional elements, and/or materials may be presented in a
common list for convenience. However, these lists should be
construed as though each member of the list is individually
identified as a separate and unique member. Thus, no individual
member of such list should be construed as a de facto equivalent of
any other member of the same list solely based on their
presentation in a common group without indications to the
contrary.
[0042] Concentrations, amounts, and other numerical data may be
expressed or presented herein in a range format. It is to be
understood that such a range format is used merely for convenience
and brevity and thus should be interpreted flexibly to include not
only the numerical values explicitly recited as the limits of the
range, but also to include all the individual numerical values or
sub-ranges encompassed within that range as if each numerical value
and sub-range is explicitly recited. As an illustration, a
numerical range of "about 1 to about 5" should be interpreted to
include not only the explicitly recited values of about 1 to about
5, but also include individual values and sub-ranges within the
indicated range. Thus, included in this numerical range are
individual values such as 2, 3, and 4 and sub-ranges such as from
1-3, from 2-4, and from 3-5, etc., as well as 1, 2, 3, 4, and 5,
individually.
[0043] This same principle applies to ranges reciting only one
numerical value as a minimum or a maximum. Furthermore, such an
interpretation should apply regardless of the breadth of the range
or the characteristics being described.
[0044] Reference throughout this specification to "an example"
means that a particular feature, structure, or characteristic
described in connection with the example is included in at least
one embodiment. Thus, appearances of the phrases "in an example" in
various places throughout this specification are not necessarily
all referring to the same embodiment.
[0045] Reference in this specification may be made to devices,
structures, systems, or methods that provide "improved"
performance. It is to be understood that unless otherwise stated,
such "improvement" is a measure of a benefit obtained based on a
comparison to devices, structures, systems or methods in the prior
art. Furthermore, it is to be understood that the degree of
improved performance may vary between disclosed embodiments and
that no equality or consistency in the amount, degree, or
realization of improved performance is to be assumed as universally
applicable.
Example Embodiments
[0046] With reference to FIG. 1, a food preparation system 100 in
accordance with an example of the present disclosure can include a
food preparation device 101 and a package 102 having a solid food
ingredient 103 disposed therein. The food preparation device 101
can have an ingredient combining apparatus 110 to introduce a fluid
food ingredient 104 and the solid food ingredient 103 to one
another within the package 102.
[0047] The food preparation device 101 can also include a mixing
apparatus 120 to mix the fluid food ingredient 104 and the solid
food ingredient 103 to form a food mixture in the package 102.
Mixing can be accomplished in any suitable manner, such as by
shaking and/or mechanical manipulation (e.g., stirring, magnetic
mixing, sonication, orbital mixing, etc.). In addition, the food
preparation device 101 can include a forming apparatus 130 to form
the food mixture into a predetermined shape within the package 102.
Advantageously, the food preparation system 100 can allow
pre-selected and pre-weighed ingredients to be contained in the
package 102 from the time of deposit into the package, through the
storage shelf life to the time of manufacture, at which time the
ingredients are formed into a food product. Furthermore, the
finished food product can remain in the package 102 up to the time
of consumption.
[0048] In one aspect, the fluid food ingredient 104 and/or the
solid food ingredient 103 can be disposed in one or more packages
or containers, which can be configured to facilitate preparation of
a food product therein (e.g., by being flexible) and disposable to
minimize or eliminate cleaning of the food preparation device 101.
In this regard, the device can be configured so as to not ever
require any cleaning, or can alternatively be configured to allow
for or otherwise require periodic cleaning. In this latter case, in
some embodiments the cleaning required may be provided for as
function performed by the device, which can be for example,
automatic, or can be manually initiated and controlled. In a
particular aspect, the solid food ingredient 103 can be contained
within the package, at least in part, by one or more frangible
seals 105. More particularly, the fluid food ingredient 104 and the
solid food ingredient 103 can be initially contained or disposed in
the package 102 within separate compartments 106a, 106b of the
package formed at least in part by separations or seals including
one or more frangible seals 105.
[0049] The food preparation device 101 can include a heating
apparatus 140 configured to heat the fluid food ingredient 104
and/or the solid food ingredient 103. The heating apparatus 140 can
heat the fluid food ingredient 104 and/or the solid food ingredient
103 sufficient to facilitate homogeneously mixing the fluid food
ingredient and the solid food ingredient, and insufficient to cook
the fluid food ingredient and the solid food ingredient. The food
preparation device 101 can also include a drying apparatus 150 to
remove moisture from the food mixture (e.g., dry the food mixture),
which can make the food mixture less sticky by changing the state
of moisture or removal of moisture. In addition, the food
preparation device 101 can include a topping dispenser 160 to apply
a topping to the food mixture formed, once formed in the
predetermined shape.
[0050] In some embodiments, aspects of which are described herein,
the food preparation device 101 can include a receptacle, a holding
element, a heating element, a piercing or cutting element, a
shaking element, an air and/or vacuum pump, a kneading element, a
pushing element (to allow the package or container with raw
ingredients to either be pushed to a different region in the device
or to push it to move/adjust all the ingredients in the package or
container to be tightly placed prior to a molding step), a
folding/turning element (to allow the package or container with raw
ingredients to be pressed and turned so as to create a snack/bar as
explained below), a molding element (to render a desired shape to
the finished product), a drying element (to dry or harden the
finished product), a cooling element (to harden or cool the
finished product), a cleaning unit or made of non-stick material,
and/or a spraying or drizzling element (to enrobe a finished
product via for example a chocolate sauce or honey or other such
topping).
[0051] The food preparation device 101 can include the receptacle
for receiving the package or container (e.g., a pouch, sack, bag,
case, pod, wrapper, etc.) that can have a lid that can actuate the
manufacturing process via opening and closing operations either
through manual or electronic means. Alternatively, the device 101
can be configured to store a type of wax paper which the user would
place at the reception to receive the finished product. The holding
element can keep the package or container in place such that the
package or container is free at one end (the vertically lower
portion in the case of a bag with two compartments placed
vertically one of top of each other, or one of the lateral ends in
the case of a bag with two or more compartments place horizontally
next to each other). The shaking element can shake and mix the
contents within the free end of the bag, which can be done with or
without the aid of an air and/or vacuum pump. The heating element
can heat the fluid component. The piercing or cutting element can
pierce or cut the wall between compartments so as to allow the
contents of one of the compartments to be mixed with the contents
of the other compartment, as discussed in more detail hereinafter.
The kneading element can allow homogeneous mixing of the fluid
component with the solid ingredients. The pushing element can
ensure that all the ingredients in the package or container can be
pulled off the walls of the package or container and pushed to one
end of the sac or bag. The molding element (pushing and pressing)
in combination with a folding and turning element can mold the
finished product within the sac or bag such that it obviates the
need for cleaning by the user. The drying element (with or without
vacuum) can help the finished product complete the binding process
and or deliver the product. The enrobing element can allow a
desired substance to add flavor or nutritional properties be
drizzled, poured, or sprayed, where a separate package or container
having an enrobing substance can be used. The freezing element can
also be used to deliver a molded product without stickiness.
[0052] A single or multiple compartment package or container can
hold selective ingredients of the recipe in each of the
compartments for desired functionality, packaged shelf life at room
temperature, as well as taste and nutrition quality. The package or
container can also serve to contain ingredients during preparation
or manufacture and/or as the package or wrapper for the finished
product. A two compartment package or container, for instance, can
be distinguished as serving to hold the solid ingredients (e.g.,
dry, particulate, powder, dried fruits, nuts, pre-cooked
ingredients, etc.) in one compartment or section (A) while the
fluid ingredients (e.g., liquid or viscous components) can be held
in a second compartment or section (B). The amount of solids and
liquid in a given package can be any amount or type needed to
achieve a specific finished product or follow a given recipe.
However, in one example solids as a function of the total package
may account for greater than 5% of the volume of the package or
container. In another example, a volume of the package or container
can be 180 cm.sup.3. Furthermore, a single or multiple compartment
package or container can include flexible and/or rigid
portions.
[0053] In one aspect, two compartments can be positioned vertically
one above the other, where section A can represent the top or
bottom section. For example, section A can represent the bottom
compartment and section B can represent the top compartment. In
another aspect, two compartments can be positioned horizontally
next to each other, where both sections are in a side by side or
parallel configuration. In practice, nearly any arrangement or
relationship between the sections or compartments that allows
proper combining of ingredients and formation into a suitable food
product using a device as recited herein can be used. An opening
can be opened or formed between the compartments to facilitate
passage of the contents of section B into section A, such as by a
manual or machine actuated piercing, puncturing, cutting action,
and/or breaking of a frangible seal between the compartments. Thus,
liquids can be evacuated into a section holding solids via gravity
(in a vertical configuration) and/or a mechanically applied force.
In one aspect, burst pouches or containers that have a seal between
the solid and fluid compartments may be broken in any suitable
manner, such as with pressure, air, steam, vacuum, microwave
energy, or heat.
[0054] In one aspect, section B can be made of materials that are
heat tolerant or heat resistant (such as heat resistant silicone)
so as to allow mild heating of its contents, namely the
liquid/viscous binding/sweetening agents, and cause these
components to flow freely. Section A and/or section B can be made
of material that is resistant to application of pressure, pull, or
other type of force and avoid potential tearing as a result of
ingredients piercing through the material during mixing and
molding. This can allow the device to remain a clean-free state.
Section A and/or section B can be made of material and/or have a
coating that does not allow their contents to be visible from the
outside unless cut open to reveal contents. In one aspect, the
compartment that corresponds to section B can have an inner layer
pre-coated with oil, glycerin, or some other non-stick material.
Section A and/or section B may be manufactured using materials with
a high moisture and oxygen barrier and creating a package or
container that has an extremely dry internal environment. The
packages or containers can be packaged with raw ingredients under a
nitrogen flush to prevent oxidative degradation during shelf life.
The package or container can be made of a flexible type of material
to allow both placing the package or container in to the device, to
be pressed and folded, and to be released appropriately subsequent
to product manufacture. Because the package or container can serve
as the finished package as well, it may be equipped with a
re-sealable or rip-able capability at one of its ends or corners
for consumer ease. The container can also be used as the delivery
package after product manufacture to allow the consumer to safely
hold and carry the finished product.
[0055] Alternatively, the fluid set and solid set of ingredients
can be made available in separate packages or containers, which
would then be used with a device compatible for insertion of two
separate packages or containers. For example, the food preparation
system can include containers (i.e., tanks, vats, etc.) of
ingredients where the fluid food ingredient and/or the solid food
ingredient can be stored until use, such as within the food
preparation device. In one aspect, delivery of the fluid and/or
solid food ingredient can be automated.
[0056] In operation, a user can place a multi-compartment package
or container in a receptacle within a food preparation device. The
package or container can be used for storage and transport of
appropriate raw ingredients, as the preparation container to
convert the set of ingredients in to a finished meal or snack
product of desired taste, form/shape, temperature, and nutritional
potential, and as the packaging material for the finished product.
Subsequently, the fluid component can be slightly heated/warmed
with or without direct contact with the heating source, such that
the fluid component can flow either by force of gravity or
mechanical aid, which can facilitate addition of the fluid
component into the solid component, mixing, binding, molding,
and/or shaping. The specific temperature depends on the specific
ingredient or combination of ingredients. For example, a
temperature of greater than 120 degrees F. may be suitable for a
mixture of honey, brown rice syrup, and oil in approximately a
35:35:30 ratio. Alternatively, the temperature increase or change
in flow behavior of the fluid component may be the consequence of
non-thermal forces, such as pressure, friction, etc.
[0057] In one aspect, no water may be added in the process and
therefore no direct hydration of ingredients is involved. Instead,
wet or fluid ingredients that have moisture can be used. However,
that moisture may be unavailable or is bound and cannot be used for
hydration in the conditions.
[0058] In another aspect, the fluid food ingredient can comprise
only water. Typically, bars cannot tolerate much water due to the
need to maintain a low water activity to prolong shelf life.
However, in this case, because the food product is made at the
point of consumption, water activity is not a limiting factor.
Thus, the food product can comprise a gel, a pudding, a soup, a
sauce, a dressing, or any food product that may involve mixing of
fluid and solid components (e.g., for rehydrating, facilitating
mixing, or otherwise contributing to the formation of a final food
product), etc.
[0059] In one aspect, the fluid and/or solid ingredients can be
heated. For example, the fluid ingredients can be heated and then
mixed with the solid ingredients. In another example, solid
ingredients can be heated and combined with the fluid ingredients
to warm the fluid ingredients so as to be fluid enough to mold. In
a particular aspect, the fluid set of ingredients can be heated up
just enough to effect pourability (transferability) due to a lower
viscosity and then mixed with a solid set of ingredients. Heat may
be used for two functions. First, to make the fluid set of
ingredients flowable (and ultimately to mix homogenously and allow
for binding) and second, to deliver a drier product and one that
maybe a slightly warmer product to the consumer than the packaged
product counterpart currently available for sale in the market.
Amount of heat used insufficient to cook, but sufficient to help
with shaping, agglomerating, and/or providing a warm food
product.
[0060] The compartment containing the solid raw ingredients can be
shaken or disturbed mechanically so as to mix all the ingredients
(which may settle down based on particle size and weight during
transport and storage) to a homogeneous or non-homogenous blend
prior to addition of the fluid component. The shaking or mechanical
disturbance can also be availed to specifically release powdered
ingredients that may be stuck in the corners of a bag or sac
holding all of the ingredients. Mixing can occur in the ingredient
container, a separate disposable container, an ingredient package,
a finished product package, and/or a washable container. Mixing
driven by motion along a single axis can result in good blending of
solid and fluid components, and along multiple axes may improve the
result. An orbital motion can result in single or multiple
spherical forms, which can then be molded in to any desired shape
including a triangular wedge-like shape. Pressure used can be very
low, just enough to mix and mold. If ingredients are in proper
proportion then pressure can be lower. In one aspect, pressurized
air may be used in the mixing process. The containers may be
pre-pressurized during packaging or pressurized by the device
during the manufacturing process. Balls/spheres may result from
mixing, which can be easily converted to a circular shape in the
form of a cookie.
[0061] The warm fluid component can be released on to the solid
components by force of gravity or mechanical aid. Alternatively,
the solid components can be released onto the fluid components by
force of gravity or mechanical aid. As a prelude to this combining
event, one of the two compartments may be pierced, slit, torn, or
punctured either by pressure or by actuating a penetrative or
ripping mechanism inherent to the device. Subsequent to combining
the fluid and solid components within one of the two compartments
of the package or container, mechanical or pressure activated force
can be used to blend all of the ingredients homogeneously. The
temperature of this blend may be warmer than room temperature as a
result of the heated fluid component. Optimal blending and binding
can occur at the appropriate temperature and this inherently
results in adhesion of all of the particles (>98% binding, i.e.,
less than 2% of the solid or liquid ingredients unbound).
Subsequent to obtaining a homogenous sticky blend of fluid and
solid ingredients, the mixture can be molded in to a desired shape,
cube (square or rectangle), sphere, pyramid, or as non-descript
shape as a cluster of ingredients. The mixture can be molded in to
a single or multiple product units. The food product can be made
into any shape. The shaping can occur due to low pressure of
molding and not because of extrusion or high pressures needed to
push product through a discharge die. Containers having round edges
(free of linear corners) may be utilized to prevent waste. After
molding, the finished product can be dried using air or other
element to hasten the binding effect and reduce stickiness of the
finished product.
[0062] In another example, a single compartment sac or bag can be
used where the inside of the bag is pre-coated with a binding agent
(approximately 5-20% of the total recipe) such as honey, brown rice
syrup, maple syrup, or corn syrup and a vegetable oil
(approximately 1-5% of the total recipe) such as sunflower oil or
olive oil. The bag can contain the remaining ingredients of the
recipe such as nuts, fruits, protein powder, flavor, etc. The
ingredients can be vigorously mixed and/or blended to coat the
ingredients with the binding agent and the oil, before it is put
through a rolling and pressing action to let ingredients bind in to
a desired shape, preferably a cylindrical type. The advantage of
this process is that it obviates the need for a heating step and a
multi-compartment package or container.
[0063] The binding agent can be a solid or a liquid in its stored
state, however, the binding effect may be manifest only in the
liquid state, mostly as a consequence of heating or pressure (heat
causes a physical transformation into a slight liquid state), which
can facilitate the adhesion of various solid ingredients.
Therefore, the binding agent may be included in the component
containing the solid set of ingredients. One recipe can be
represented by a 0% liquids in the package or container, where in
the recipe still includes the binding agent, but in solid state,
and such a recipe can be used through the application of heat to
realize a binding action on the finished product.
[0064] Subsequent to molding the product, the product can be
enrobed or drizzled with a viscous liquid that hardens such as
chocolate sauce or honey from a separate container with the
appropriate actuation system. Alternatively, the product can be
enrobed or drizzled with a desired substance outside this process
and/or intended device, such as by dipping or mixing the product in
milk, chocolate sauce, and/or a savory sauce. In the finished
product, heat can be used to keep product warm and dry. In one
aspect, a food product can comprise two or more stacked layers,
which layers can be formed independently of the same or different
ingredients.
[0065] As mentioned above, where two separate packages or
containers containing solid and fluid ingredients are used, the
process can include separate opening of the two packages, the
heating of the fluid package to make liquid components flow-able in
to the package consisting of the solid ingredients. Alternatively,
the package having the fluid ingredients can be heated and the
contents of the package having the solid ingredients can be emptied
in to the package consisting of the fluid ingredients. Therefore,
the molding of the snack or bar product can occur within either of
the packages to remain a clean free system. In one aspect, a
package can also serve as a shaping aid, in addition to storing the
fluid food ingredient and/or the solid food ingredient.
[0066] Alternatively, the bar or snack can be molded in a separate
compartment of the device which can receive both the solids and
fluid ingredients either individually or combined. Such a
compartment can be made of a non-stick material that can be easy to
clean by way of steam, water, other substances, or by
manual/mechanical means.
[0067] As disclosed herein, the final food product can be made
using low pressure, low heat such that no cooking occurs (only mix,
mold), with or without hydration in a short time. The final food
product can be provided on demand and produced from pre-formulated
food material stored within a package or container of fresh, ready
to eat food. The final food product can be a nutritionally relevant
snack or meal to meet specific dietary requirements such as need
for immediate energy through carbohydrate, muscle mass and recovery
through protein, specific nutritional components such as vitamins,
minerals, fiber, and whole grains, or delivering specific health
and lifestyle benefits including antioxidant or weight management
properties. The final food product may be unavailable to consumers
without significant pre-work, preparation, and manufacture in the
home or other location. The final food product can therefore offer
consumers a product that is highly palatable due to its freshness,
softness, potential moistness, and potential warmth at consumption.
A warm, moist, fresh tasting snack is currently not available in a
convenient, single serve form while also providing and meeting
nutritional needs.
[0068] In one aspect, the final food product can be configured as a
single serve item representing the perception of a fresh snack or
meal product for instant (ready to eat) or future consumption. In
another aspect, the final food product can be configured to provide
the perception of a home-made, fresh snack/bar for a breakfast or
other meal or non-meal occasion.
[0069] The final food product can be a manufactured snack/bar or a
manufactured snack/bar as it is delivered in a package or
container. The final food product can be served warm or at room
temperature or as cold product. The final food product can be
provided in several consistencies, such as a bar-like product that
ranges from brittle, hard, soft and chewy, or non-bar-like
products, such as puddings, gels, emulsions, etc. In one aspect,
the final food product can be further processed/flavored etc. after
it is released from the device, for example, the final food product
may be dipped into milk and consumed. In another aspect, the final
food product can be delivered in a shape (such as a stick or other
form) that is easy to dip in to a viscous substance or a liquid
(such as honey, chocolate sauce, milk, etc.) and/or enrobed outside
the device with a desired flavor or nutrient endowing substance. In
yet another aspect, the final food product can be crumbled and
consumed. In still another aspect, the final food product can be
received after preparation on a pre-cut parchment paper, wax paper,
or like material.
[0070] FIG. 2 illustrates a food preparation device 201 in
accordance with an example of the present disclosure. The food
preparation device 201 can include a heating apparatus 240, an
ingredient combining apparatus 210, a mixing apparatus 220, and a
forming apparatus 230. In addition, the food preparation device 201
can include a package securing mechanism 270 to secure a package
(not shown in this figure) during operation of the food preparation
device.
[0071] In one aspect, the mixing apparatus 220 can comprise an
orbital shaker. For example, the mixing apparatus 220 can include a
package support 221 to provide support for the package while
forming the food mixture. The package support 221 can be mounted to
rotary members 222a-d that can be configured to guide or move the
package support in an orbital motion. In one aspect, one or more
rotary members can provide drive input to cause the orbital motion
of the package support 221.
[0072] In one aspect, the package securing mechanism 270 can
comprise a clamp configured to engage a portion of the package to
hold or secure the package during the operations performed by the
food preparation device 201 to prepare a food product. For example,
the package securing mechanism 270 can include clamp portions 273a,
273b configured to engage opposite sides of the package when the
package is disposed on the package support 221. Each clamp portion
273a, 273b can include a lower clamp jaw 271a, 271b and an upper
clamp jaw 272a, 272b. Thus, the package securing mechanism 270 can
secure the package on the mixing apparatus 220.
[0073] A locking mechanism 274 can also be included to facilitate
locking the lower clamp jaws 271a, 271b and the upper clamp jaws
272a, 272b to maintain the package in a secured configuration
during operation of the device 201. For example, the locking
mechanism 274 can include a pin 275a, 275b extending from the upper
clamp jaws 272a, 272b, and a receiving member 276a, 276b pivotally
coupled to the lower clamp jaws 271a, 271b, respectively. The
receiving member 276a, 276b can have an opening 277a, 277b
configured to receive the pin 275a, 275b and secure the pin by
mechanical interference upon pivoting of the receiving member. The
receiving member 276a, 276b can be configured to pivot into a
locking position under force from the pin 275a, 275b. A release
feature 278a, 278b can extend from the receiving member 276a, 276b
to facilitate pivoting the receiving member to a release position
to release the pin 275a, 275b from the opening 277a, 277b. The
release feature 278a, 278b can be interface with a door or lid (not
shown in this figure) to release the locking mechanism 274 upon
opening the door or lid by a user of the device 201.
[0074] In one aspect, the ingredient combining apparatus 210 can
comprise a pressurized fluid source 211 fluidly coupleable to the
package to provide pressurized fluid, such as gas (heated or
otherwise), to break a frangible seal. This gas could be filtered
and/or purified to prevent ingredient contamination using HEPA
filters, ultraviolet light, etc. In the illustrated embodiment,
such a fluid coupling can be made by way of the package securing
mechanism 270. For example, the lower clamp jaw 271a can include a
fluid port 212 configured to interface with the package to fluidly
couple the pressurized fluid source 211 and the package. In
addition, a fluid coupler 213 can be configured to engage and
interface with a portion of the package support 221 to provide a
fluid connection with the package support 221 and the fluid port
212. As explained in more detail below, the rotary members 222a-d
can position the package support 221 proximate the fluid coupler
213 to facilitate a fluid connection with the pressurized fluid
source 211.
[0075] The heating apparatus 240 and the forming apparatus 230 can
be mounted on a pivoting arm 280 that is actuatable by an actuator
281 to extend and retract the heating apparatus 240 and the forming
apparatus 230 at appropriate stages of operation of the food
preparation device 201, which are described in more detail below.
An actuator or motor 231 can provide force and/or torque to operate
the forming apparatus 230.
[0076] With continued reference to FIG. 2, FIGS. 3A and 3B are
front views of the food preparation device 201, showing certain
features of the device that are hidden from the view of FIG. 2. For
example, the forming apparatus 230 can include a die to form the
food mixture into the predetermined shape. In one aspect, the die
can comprise two dies 232a, 232b movable relative to one another to
form the food mixture into the predetermined shape. FIG. 3A shows
the dies 232a, 232b separated from one another, which may represent
a starting position for the dies when first engaging the food
mixture to form a predetermined shape. FIG. 3B shows the dies 232a,
232b proximate one another, which may represent a finishing
position for the dies when the predetermined shape has been formed.
The dies 232a, 232b can apply any suitable pressure that may be
desired to form a final shape of a food product. Typically, a
pressure of from about 2 psi to about 25 psi will be applied to
form the food mixture into the final shape, although pressures
outside this range may be applied. In a particular example, the
pressure applied by the dies 232a, 232b can be about 11 psi. The
applied pressure can vary depending on the recipe.
[0077] The heating apparatus 240 can include a heating element 241,
which can be disposed in a shroud 242 that can be configured as a
heat shield and may be at least partially insulated to protect
other components of the device 201 from heat. The heating apparatus
240 can be configured to generate heat in any suitable manner. In
one aspect the heating apparatus 240 can comprise a resistance
heater, a convection heater, a radiant heater, or a combination
thereof. In a particular aspect, the heating apparatus 240 can
comprise a nichrome heater. A sensor 243 can be included to
determine whether the fluid and/or solid food ingredient and/or the
package have been heated sufficiently. Any suitable sensor may be
utilized for sensing and/or measuring heat or thermal
characteristics, such as a thermopile sensor, an infrared sensor,
etc.
[0078] In one aspect, the clamp portions 273a, 373b can be
pivotally coupled to the package support 221 to facilitate
inflation and deflation of the package 202. In other words, the
clamp portions 273a, 373b can be movable to accommodate inflation
of the package by pressurized fluid. For example, the clamp
portions 273a, 373b can be rotatable inward in direction 274a, 274b
to accommodate a decrease in a lateral dimension of the package as
the package increases in thickness, due to inflation of the package
by the pressurized fluid source 211. The package support 221 can be
configured to facilitate such rotational movement of the clamp
portions 272a, 273b by providing a gap 223a, 223b into which the
clamp portions can move. Springs 275a, 275b can bias the clamp
portions outward, opposite direction 274a, 274b. A minimum inflated
thickness or "pillowing" of the package may facilitate successful
mixing of the fluid and solid ingredients. A sensor can be used to
determine whether the package has been sufficiently inflated. For
example, a sensor can be used to determine internal pressure of the
package or an outer dimension of the package to ensure that the
package has achieved a minimum amount of pillowing or inflation. In
one aspect, the movement of the clamp portions 273a, 273b can be
related to a sufficient amount of inflation of the package. In this
case, a sensor 276 (e.g., an IR sensor) can be used to determine
whether the clamp portions 273a, 273b have moved inwardly in
direction 274a, 274b to an extent that indicates that the package
has been adequately inflated. In addition, movement of the clamp
portions 273a, 273b can facilitate determining whether the
frangible seal in the package has been broken. It should be
recognized that the food preparation device 201 can include any
suitable type of sensor in any suitable quantity to facilitate
operation of the device as described herein. Such sensors can
include position sensors, pressure sensors, force sensors,
accelerometers, thermal sensors, optical sensors, or any other
suitable type of sensor.
[0079] FIG. 4 illustrates a food preparation system 200 in
accordance with an example of the present disclosure. The system
200 can include the food preparation device 201 described above. In
this case, the device 201 is shown with a housing 290 disposed
about the various components of the device previously described,
such as the ingredient combining apparatus, the mixing apparatus,
and the forming apparatus. A receptacle 291 can be defined within
the housing 290 to receive a package 202. The package 202 can
include compartments 206a, 206b that can contain a fluid food
ingredient and a solid food ingredient, respectively. The
compartments 206a, 206b can be separated at least in part by a
frangible seal 205. When the package 202 is in the receptacle 291,
any of the various components of the food preparation device 201
may be operable on the package. The housing can also include a lid
or door 292 for the receptacle 291. In one aspect, operation of the
food preparation device 201 can be initiated by closing the lid 292
when the package 202 is disposed in the receptacle 291. In another
aspect, a start button can be pushed to initiate operation of the
device 201. From that point, the rest of the process can be
automatically controlled via microprocessor. The process can also
be started with an integral timer. The user can load the package
202 into the device 201 and set the desired start time.
[0080] Different food formulations, different serving sizes, and
different extrusion dies all may require different cooking times,
temperatures, and pressures. The package 202 may be affixed with
one of a plurality of possible "sensory" devices which will
indicate to a "reader" installed in the food preparation device 201
the desired cooking regimen, i.e., each individual package may have
an attached bar code containing process parameters (mix time,
mixing speed, pressure, temperature, etc.) unique to the intended
finished food product. The code can be read by the device's control
system at the beginning of the process, as more fully described
herein below.
[0081] There are a variety of possible sensory devices that may be
used. Possibilities include but are not limited to various
barcodes, magnetic strips, conductive or resistive elements,
resonant devices, physical features (e.g., bumps or depressions in
the container, and RFID chips). It is also apparent that the cost
of such features may preclude their use in which case it may fall
to the user of the appliance to select a cooking procedure using a
keypad or other type of user input device.
[0082] The devices disclosed herein may be designed and sized as a
home or commercial appliance for conveniently producing single
and/or multiple servings of nutritious, freshly made food products
for humans or pets. Packages containing food ingredients can be
provided with ingredients formulated in accordance with a variety
of recipes.
[0083] FIGS. 4-14 will be referred to in order to describe the use
or operation of the food preparation device 201. For example, in
use, the package 202 can be disposed in the receptacle 291 such
that an inlet port 207 of the package is disposed on or proximate
to the fluid port 212. This configuration of the package 202 and
the food preparation device 201 is shown in FIG. 5, in which the
housing 290 has been removed for clarity. At this point, the user
can close the lid or door 292, which can initiate or allow
operation of the device 201. The package support 221 can be
positioned forward toward the lid or door of the device 201, which
can facilitate access to the package support by the user for
placement and retrieval of the package 202. Once the package has
been appropriately placed on the package support 221, the actuator
281 can cause the arm 280 to move downward such that extension
members 282a, 282b contact the upper clamp jaws 272a, 272b, as
shown in FIG. 6 (the package 202 has been omitted). The actuator
281 continues to move downward until the upper clamp jaws 272a,
272b and the lower clamp jaws 271a, 271b are locked to one another
by the locking mechanism 274, thus securing the package 202 on the
package support 221, as shown in FIG. 7. In the configuration shown
in FIG. 7, the heating apparatus 240 is located above the
compartment 206a that contains the fluid food ingredient. The
heating apparatus 240 can therefore heat the fluid food ingredient
to a desired temperature or temperature range, as described herein.
For example, the heating apparatus can heat the fluid food
ingredient to a temperature of about 80 degrees C. Heating may take
place for any suitable length of time. Typically, heating will
occur for about 2 second up to about 60 seconds. In a particular
example, heating may occur for up to about 45 seconds. Once the
fluid food ingredient has been sufficiently heated, the actuator
281 can raise the arm 280 to retract the heating apparatus 240 and
the mixing apparatus 220 and provide clearance for the package
support 221 and package 202 to move to a rearward position, as
shown in FIG. 8.
[0084] As shown in FIGS. 9A and 9B, the elevated position of the
arm 280 can be configured to cause retraction of the fluid coupler
213 (FIG. 9A) or extension of the fluid coupler 213 (FIG. 9B). For
example, the fluid coupler 213 can be carried by a pivot arm 214
pivotally coupled at pivot 215 to a rear support member 283. The
arm 280 can also be pivotally coupled to the rear support member
283 at pivot 284. A spring 286 can bias the pivot arm 214 forward
such that the fluid coupler 213 extends forward to contact a valve
216 on the package support 221. An extension member 285, which can
include a roller, can extend from a back of the arm 280 to contact
the pivot arm 214 when the arm 280 is sufficiently elevated. Thus,
when the package support 221 is to be moved, such as for
positioning the package or for mixing, the arm 280 can be elevated
sufficient to cause the fluid coupler 213 to be moved rearward and
clear of unwanted inference, as shown in FIG. 9A. On the other
hand, when the package is to be coupled to the pressurized fluid
source or fluid is to be removed from the package, the package
support 221 can be moved to the rearward position, and the arm 280
can be lowered sufficient to allow the fluid coupler 213 to move
forward and engage the valve 216, as shown in FIG. 9B. The arm 280
may still be elevated sufficient to provide clearance for the
package, which may be inflated. Alternatively, the fluid coupler
213 can be moved by an actuator (not shown).
[0085] FIGS. 10 and 11 illustrate inflation of the package 202,
such as when the package support 221 and the arm 280 are in the
position shown in FIG. 9B. In this configuration, pressurized fluid
is introduced to the package, which can break the frangible seal
between compartments, thereby introducing the fluid food ingredient
to the solid food ingredient. As mentioned above, the clamp
portions 273a, 273b can rotate inwardly due to the inflation of the
package 202. When sufficient movement of the clamp portions 273a,
273b has been detected by the sensor 276 indicating that the
package 202 has been adequately inflated to facilitate proper
mixing of the fluid and solid food ingredients, the supply of
pressurized fluid from the pressurized fluid source 211 can be
terminated. At this point, the arm 280 can elevate provide the
configuration shown in FIG. 9A, such that the fluid coupler 213 is
retracted from the package support 221 and clearance is provided
for operation of the mixing apparatus. As shown in FIG. 12, the
rotary members 222a-d can guide or move the package support 221 in
an orbital motion to mix the fluid and solid food ingredients into
a food mixture within the package 202. Orbital motion of the
package support 221 can be at any suitable speed. In one aspect,
orbital motion of the package support 221 is at 350 RPM. Mixing may
take place for any suitable length of time, which may vary
depending on the recipe. Typically, mixing will occur for at least
45 seconds and less than about 3 minutes, although mixing times
outside of this range are possible.
[0086] When mixing is done, the package support 221 is moved to the
rearward position where the arm 280 is lowered to an intermediate
position, as shown in FIG. 9B, such that the fluid coupler 213
engages the valve 216. In this configuration, fluid (typically gas)
can be removed from the package to facilitate shaping or forming
the food mixture into a desired final shape while inside the
package. Once a sufficient amount of fluid has been removed from
the package, the forming apparatus 230 is lowered by actuation of
the actuator 281 to the configuration shown in FIG. 13. FIG. 14
shows a final position of the dies 232a, 232b. The package has been
omitted for clarity. The dies 232a, 232b move inward to shape the
food product. The dies 232a, 232b operate external to the package
to form the food mixture into a desired shape within the package.
The dies 232a, 232b can move inward to facilitate forming the final
shape of the food product any suitable number of times. In one
aspect, the dies 232a, 232b move inward only a single time to form
the final shape of the food product.
[0087] When a final shape is achieved, the arm 280 can elevate to
the configuration shown in FIG. 9A. The package support 221 can
then move to a forward position, where the locking mechanism 274
can be released, such as by action of the user opening the door or
lid 292. Optionally, the locking mechanism 274 can be released by
an actuator. The upper clamp jaws 272a, 272b can be biased upward
by a spring to facilitate removal of the package from the device
201 by the user. The user can then retrieve the package with a
finished food product inside. The package can then serve as a
wrapper for the food product, which can temporarily protect the
food product and from which the food product can be consumed.
[0088] FIG. 15 illustrates dies 332a, 332b that can be configured
to form a plurality of predetermined shapes. For example, die
portions 333a, 333b can be configured to form one shape and die
portions 334a, 334b can be configured to form another shape. The
dies 332a, 332b can be rotatably coupled to die supports 335a,
335b. Thus, a different shape can be achieved by rotating the dies
332a, 332b to expose a desired die portion to the operating
position. Although two predetermined shapes are represented in the
figure, it should be recognized that any suitable number of
predetermined shapes can be formed by rotatable dies as shown and
described.
[0089] FIG. 16 illustrates a bottom view of a mixing apparatus 420.
In this case, a drive rotary member (hidden from view) can be
coupled to a motor to provide drive torque for an orbital mixer.
Guide rotary members 422a-d can be passive and can serve to guide
the movement of a package support. The drive rotary member can be
coupled to a positioning device 424, which can have a disc 425 with
a plurality of tabs 426 that can be sensed by sensors 427a, 427b.
The positioning device 424 can be used to determine a position of
the package support and facilitate proper positioning of the
package support for the various operations of a food preparation
device as disclosed herein.
[0090] FIG. 17 illustrates a food preparation device 501 in
accordance with another example of the present disclosure. In this
case, the device 501 includes a drying apparatus 550 to remove
moisture from a food mixture (e.g., a final food product) within a
package. In addition, the device 501 include a package opening
apparatus 594 to create an opening in the package to facilitate the
removal of moisture from the food mixture by the drying apparatus
550. The package opening apparatus 594 can comprise a cutter, such
as a knife or blade. A package support 521 can include a recess
595, such as a channel or groove to provide clearance for the
cutter when creating the opening in the package. The drying
apparatus 550 can be positioned proximate the opening to direct air
into the opening of the package. The drying apparatus 550 can
include a blower to provide air at ambient temperature and,
optionally, a heater, to provide hot air, and/or cooling system to
provide cold air or cryogenic air.
[0091] In one aspect, the device 501 can include a sealer 596 to
seal an opening created by the package opening apparatus 594. Thus,
an excess of package material can be removed by the package opening
apparatus 594, such as an empty compartment or other portion of the
package that does not contain the final food product, and the
sealer can form a seal around the final food product. The package
can therefore be reduced in sized and formed into a relatively
compact wrapper for the food product, which can then be saved for
later consumption.
[0092] The device 501 also illustrates a needle 597 that can be
used to introduce fluid (e.g., gas heated or otherwise) to the
package and/or remove fluid from the package. The needle 597 can be
actuated to move upward into the package through a hole or opening
in the package support 521.
[0093] FIGS. 18A-18G illustrate several views of an exterior design
of a food preparation device in accordance with an example of the
present disclosure.
[0094] Recipes presented herein may represent snack or meal
formulations having a pre-mixed blend of ingredients. The
formulations have a single set of all ingredients or can be divided
into multiple sets of ingredients. One of these sets includes the
solid and/or partially dry ingredients, while another set of
ingredients includes the fluid or partially liquid/viscous
materials in the recipe. In one aspect, another set of ingredients
includes the highly powdered components. Alternatively, the sets of
ingredients can be distinguished based on requirement for heating.
For example, some of the ingredients may be too viscous and need to
be heated sufficiently for flow-ability, homogeneous mixing, and
improved functionality, such as ingredient binding. In one aspect,
some of the ingredients may be used to elicit an adhesive effect on
the remaining ingredients. In another aspect, some of the
ingredients may be used to release the finished product with ease
from the package, bag, or container which was used to mix, bind,
and mold the ingredients.
[0095] Recipe 1: (Cereal or Granola Based Products)
[0096] Dry component can include cereals like rolled oats or
granola clusters, and a liquid binding agent (honey, Brown Rice
Syrup (BRS), and or any other sweetening syrup).
[0097] Cereal or granola (60-90%), binding agent (10-40%) (single
or a combination of varying amounts of multiple binding agents) Ex:
honey (5-30%) BRS (5-30%), Oil (0.5-4%).
[0098] Cereal or granola (up to 60%), binding agent (up to 40%)
(Single or a combination of varying amounts of multiple binding
agents), example: honey (18%) BRS (18%)), Oil (up to 4%).
[0099] A simpler version of the above recipe: Granola/rolled oats
(80%), honey/BRS (19%), Oil (1%) can make a drier and less sticky
product.
[0100] Butter, nut butters such as almond or coconut butter for
example were used in the recipe at levels ranging between 2-20% for
adhesion and easy release of the product.
[0101] The dry components can have a water activity of <0.65 and
the fluid components can have a water activity of <0.65 to endow
shelf stability and quality extension in their pre-product
state.
[0102] Flavors, colors, other minor ingredients can also be
included for specific taste and visual appeal.
[0103] Notes:
[0104] Excessively high levels of cereal or granola can result in
poor adhesion, become too dry, and crumble too easily and difficult
to mold.
[0105] Excessively high levels of binding agent can result in
undesirable stickiness of the finished product and inability to
release the product.
[0106] Excessively high levels of oil can result in undesirable
stickiness and greasiness.
[0107] Recipe 2: (Products Containing Large Amounts of Fruits and
Nuts).
[0108] Includes nuts (chopped or whole) (single nut type or varying
combinations of cashews, almonds, peanuts, walnuts), dried fruits
(dates, cranberries, cherries), and a binding agent (honey, BRS)
and a few drops of oil (safflower oil).
[0109] Nuts (30-60%), dried fruits (30-60%), binding agent (1-5%)
but ideally consisted of nuts (48%), dried fruits (48%), binding
agent (4%).
[0110] Fruits can possess sufficient adhesion properties but nuts
are too dry. To ensure adhesion, nuts and even fruits can be
pre-coated with a small amount of binding agent prior to
packaging.
[0111] Ingredients can help with the adhesion process during
product manufacture, improved shelf life, and taste quality.
[0112] Nuts and/or fruits may also be pre-coated with a small
amount of the oil component(s) prior to filling other ingredients
to help with ease of mixing and efficiency.
[0113] Nuts in particular can be pre-coated with glycerin (and can
be with other binding agent) prior to packaging them to help with
binding during the preparation process.
[0114] Notes:
[0115] Excessively large particulate sizes of cereal, granola or
nuts may result in poor adhesion, become too dry and crumble too
easily.
[0116] A powdered binding agent, such as cane sugar, that liquefies
on application of mild amounts of heat can be used.
[0117] In either of the recipes types (1 and 2) above, the
ingredients, particularly the solid components can be consumed in
their raw state without prior processing.
[0118] Recipe 3 (Products Containing High Levels of Powder Such as
Protein Powder, Fiber Powder, and Sweetener):
[0119] This recipe includes a powdered ingredient representing
proteins such as those derived from dairy, plants, microbes, and
animals (sweet or acid whey powder, whey protein concentrate, whey
protein isolate, milk protein isolate, milk protein concentrate,
sodium or potassium caseinate, skim milk powder, cream powder, soy
protein isolate, soy protein concentrate, wheat protein, canola
protein, pea protein, algal protein etc.), fibers such as chicory
root, inulin, and sweeteners such as cane sugar, corn syrup, and
natural and artificial high intensity sweeteners.
[0120] The content of powdered protein (of a single type or a
combination of several types), for example, can be in the range of
15-50% of the recipe and used along with nuts such as chopped
almonds, peanuts, walnuts, pecans, etc. (in the range of 5-15%).
The binding of protein and nuts can be facilitated by viscous
liquid sweetening agents such as honey, brown rice syrup, agave
nectar, etc. (used in the range of 25-45%). Mild heating of these
liquid agents prior to addition to the proteins and nuts can
enhance uniformity of application and binding action. A small
amount of an oil component used in the range of 2-6% can help to
release the finished product with ease from the package, bag, or
container which was used to mix, bind, and mold protein and
nuts.
[0121] The particle size of nuts in a high protein product as
described above can be similar to that used in a lower protein
(fruit/cereal) type bar (but can be larger as well).
[0122] Fluidity of the liquid component used for sweetening and
more particularly for binding can contribute to a more uniform high
protein product. Such fluidity can be attained by ensuring
sufficient heat is applied to this component, but a controlled
amount such that the fluid component does not necessarily come to
boil. For example, a blend of honey, brown rice syrup and oil in
the ratio of 35:35:30 at room temperature (70.degree. F.) can
correspond to a viscosity of >5000 cps (5000-25000 cps) and the
same blend when heated to >120.degree. F. (between 10-15 seconds
in a microwave at high heat setting based on a mass range of 15-20
g of the blend) can correspond to a viscosity of <5000 cps
(500-5000 cps). A time of microwave heating greater than 15 seconds
can result in boiling of this blend.
[0123] Particle size of nuts and dried fruits can influence the
amount of liquid oil needed to obtain a balance between moistness
for binding (adhesion between ingredients) and release (lack of
adhesion to container) and product dryness to prevent stickiness.
The combination of this balance with the right amount of heat and
mechanical pressure can result in a product of desired physical
characteristics not limited to homogeneity, shape, thickness, and
overall size. The other fluid ingredients may play a role in
determining the binding action but may not contribute significantly
to the release of finished product (separation from
container/pouch/package).
[0124] Ultimately, the choice of specific ingredients determined
the microbial safety of the packaged ingredients, and general shelf
life of ingredients, palatability of the combination at specific
levels, and unique nutritional properties and benefits during
ambient storage conditions. Separation of the solid particles and
fluid ingredients in separate chambers can allow the individual
sets of recipe ingredients to maintain taste and aroma qualities
when used to manufacture the finished product.
[0125] When specific solids ingredients are pre-coated with a
binding agent, such as granola or nuts coated with corn syrup or
brown rice syrup or honey, then let to dry, and used alone (without
a fluid set of ingredients), then the solids set of ingredients can
be used directly without a separate fluid set of ingredients. The
heating step can ensure that the syrup pre-coats on to granola or
nuts to serve as the binding agent.
[0126] Caffeine may be used in an amount to simulate the energy
derived from a cup of coffee to provide a coffee hit of caffeine in
a solid form factor.
[0127] The formulations can represent pre-made combination(s) or
cluster(s) of two or more ingredients from one of the recipes
above.
[0128] In accordance with one embodiment of the present invention,
a method for preparing a food product is disclosed. The method can
comprise obtaining a package having a solid food ingredient
disposed therein. The method can also comprise introducing a fluid
food ingredient and the solid food ingredient to one another within
the package. The method can further comprise mixing the fluid food
ingredient and the solid food ingredient to form a food mixture in
the package. Additionally, the method can comprise forming the food
mixture into a predetermined shape within the package. It is noted
that no specific order is required in this method, though generally
in one embodiment, these method steps can be carried out
sequentially.
[0129] In one aspect of the method, the solid food ingredient can
be contained within the package by a frangible seal. In another
aspect of the method, the fluid food ingredient and the solid food
ingredient can be disposed in the package in separate compartments
of the package formed at least in part by the frangible seal. In
another aspect of the method, introducing the fluid food ingredient
and the solid food ingredient to one another within the package can
comprise providing a pressurized fluid to one of the compartments
to break the frangible seal. In another aspect of the method,
forming the food mixture can comprise applying pressure to the food
mixture. In another aspect of the method, applying pressure to the
food mixture can comprise molding the food mixture. In another
aspect of the method, molding the food mixture can comprise
compressing the food mixture with a die into the predetermined
shape. In another aspect of the method, mixing the fluid food
ingredient and the solid food ingredient to form the food mixture
in the package can comprise shaking the fluid food ingredient and
the solid food ingredient.
[0130] In one aspect, the method can further comprise heating at
least one of the fluid food ingredient and the solid food
ingredient. In one aspect of the method, heating can be sufficient
to facilitate homogeneously mixing the fluid food ingredient and
the solid food ingredient, and insufficient to cook the fluid food
ingredient and the solid food ingredient. In another aspect of the
method, the fluid food ingredient can be in a solid state prior to
heating. This may yield food products such as salad dressing,
(e.g., ranch or Italian dressing) where dry blends are mixed with a
liquid blend (water, oil, vinegar, and acid) or water only. An
example recipe can include salt 0.5%, dried garlic 1%, modified
food starch 1.5%, spices (dill, parsley) 0.5%, maltodextrin 2%,
black pepper 0.25%, buttermilk powder 2.5%, egg yolk powder 0.5%,
dried flavor 1.0%, Sugar 1.0%, guar gum 0.25%, lactic acid 0.5%
encapsulated oils 5%, water 82.5%, and distilled white vinegar
1%.
[0131] It could also result in a product like cheese sauce, where
dry blends are mixed with water to form an emulsion. An example
recipe can include salt 0.5%, mustard powder 0.25%, modified food
starch 1.5%, spices 0.5%, maltodextrin 2%, cheese powder 3%, whey
powder 2.5%, dried flavor 1.0%, guar gum 0.25%, lactic acid 0.5%
encapsulated oils 5%, and water 82%.
[0132] In one aspect, the method can further comprise drying the
food mixture to remove moisture from the food mixture. In one
aspect of the method, drying the food mixture can comprise moving
air about the food mixture. In another aspect of the method, drying
the food mixture can comprise applying heat to the food mixture. In
another aspect of the method, the fluid food ingredient can
maintain the food mixture in the predetermined shape upon cooling.
In an additional aspect, the food mixture may be dried to a point
that its exterior tack is reduced. Hence, in one embodiment, the
food mixture (e.g. final food product) can be dried to a point that
a degree of external tack or tackiness is reduced as compared to
prior to commencement of drying.
[0133] In one aspect, the method can further comprise applying a
topping to the food mixture formed in the predetermined shape. In
one aspect of the method, the solid food ingredient can comprise a
plurality of solid food ingredients, and the method can further
comprise mixing the plurality of solid food ingredients to form a
homogeneous blend of solid food ingredients.
[0134] In one aspect of the method, the package can contain the
food mixture until consumed. In another aspect of the method, the
package can be flexible. In another aspect of the method, the
package can be disposable.
[0135] In one aspect of the method, a volume ratio of the solid
food ingredient to the fluid food ingredient can be between about
65:35 and about 95:5. In another aspect of the method, mixing can
be completed in less than about 3 minutes, in some aspects, less
than about 1 minute, in an additional aspect, less than about 50
seconds.
[0136] The following examples pertain to further specific invention
embodiments.
[0137] In one example there is provided a food preparation device,
comprising:
[0138] an ingredient combining apparatus to introduce a fluid food
ingredient and a solid food ingredient to one another within a
package;
[0139] a mixing apparatus to mix the fluid food ingredient and the
solid food ingredient to form a food mixture in the package;
and
[0140] a forming apparatus to form the food mixture into a
predetermined shape within the package.
[0141] In one example of a food preparation device, the package
initially includes the solid food ingredient contained at least in
part by a frangible seal.
[0142] In one example of a food preparation device, the fluid food
ingredient and the solid food ingredient are initially contained
within separate compartments of the package formed at least in part
by the frangible seal.
[0143] In one example of a food preparation device, the ingredient
combining apparatus comprises a pressurized fluid source fluidly
coupleable to the package to provide pressurized fluid to one of
the compartments to break the frangible seal.
[0144] In one example of a food preparation device, the device
further comprises a package securing mechanism to secure the
package during operation of the food preparation device.
[0145] In one example of a food preparation device, the package
securing mechanism comprises a fluid port configured to interface
with the package to fluidly couple the pressurized fluid source and
the package.
[0146] In one example of a food preparation device, the package
securing mechanism comprises a clamp configured to engage a portion
of the package.
[0147] In one example of a food preparation device, at least a
portion of the clamp is movable to accommodate inflation of the
package by the pressurized fluid.
[0148] In one example of a food preparation device, movement of the
clamp facilitates determining whether the frangible seal has been
broken.
[0149] In one example of a food preparation device, the mixing
apparatus comprises an orbital shaker.
[0150] In one example of a food preparation device, the mixing
apparatus further comprises a package support to provide support
for the package while forming the food mixture.
[0151] In one example of a food preparation device, the forming
apparatus comprises a die to form the food mixture into the
predetermined shape.
[0152] In one example of a food preparation device, the die
comprises two dies movable relative to one another to form the food
mixture into the predetermined shape.
[0153] In one example of a food preparation device, the dies are
configured to form a plurality of predetermined shapes.
[0154] In one example of a food preparation device, the device
further comprises a heating apparatus configured to heat at least
one of the fluid food ingredient and the solid food ingredient.
[0155] In one example of a food preparation device, the heating
apparatus is configured to provide heat sufficient to facilitate
homogeneously mixing the fluid food ingredient and the solid food
ingredient, and insufficient to cook the fluid food ingredient and
the solid food ingredient.
[0156] In one example of a food preparation device, the heating
apparatus comprises a resistance heater, a convection heater, a
radiant heater, or a combination thereof.
[0157] In one example of a food preparation device, wherein the
device further comprises a drying apparatus to remove moisture from
the food mixture.
[0158] In one example of a food preparation device, the drying
apparatus comprises at least one of a blower, a heater, and a
cooling system.
[0159] In one example of a food preparation device, the device
further comprises a package opening apparatus to create an opening
in the package to facilitate removal of moisture from the food
mixture by the drying apparatus.
[0160] In one example of a food preparation device, the package
opening apparatus comprises a cutter.
[0161] In one example of a food preparation device, the device
further comprises a housing disposed about the ingredient combining
apparatus, the mixing apparatus, and the forming apparatus.
[0162] In one example of a food preparation device, the device
further comprises a receptacle within the housing to receive the
package, wherein at least one of the mixing apparatus and the
forming apparatus are operable on the package when in the
receptacle.
[0163] In one example of a food preparation device, the device
further comprises a lid for the receptacle, wherein operation of
the food preparation device is initiated by closing the lid when
the package is disposed in the receptacle.
[0164] In one example of a food preparation device, the device
further comprises a topping dispenser to apply a topping to the
food mixture formed in the predetermined shape.
[0165] In one example, there is provided a food preparation system,
comprising:
[0166] a package having a solid food ingredient disposed therein;
and
[0167] a food preparation device, having
[0168] an ingredient combining apparatus to introduce a fluid food
ingredient and the solid food ingredient to one another within the
package,
[0169] a mixing apparatus to mix the fluid food ingredient and the
solid food ingredient to form a food mixture in the package,
and
[0170] a forming apparatus to form the food mixture into a
predetermined shape within the package.
[0171] In one example of a food preparation system, the solid food
ingredient is contained within the package by a frangible seal.
[0172] In one example of a food preparation system, the fluid food
ingredient and the solid food ingredient are disposed in the
package in separate compartments of the package formed at least in
part by the frangible seal.
[0173] In one example of a food preparation system, the ingredient
combining apparatus comprises a pressurized fluid source fluidly
coupleable to the package to provide pressurized fluid to one of
the compartments to break the frangible seal.
[0174] In one example of a food preparation system, the mixing
apparatus comprises an orbital shaker.
[0175] In one example of a food preparation system, the forming
apparatus comprises a die to form the food mixture into the
predetermined shape.
[0176] In one example of a food preparation system, the system
further comprises a heating apparatus configured to heat at least
one of the fluid food ingredient and the solid food ingredient.
[0177] In one example of a food preparation system, the system
further comprises a drying apparatus to remove moisture from the
food mixture.
[0178] In one example of a food preparation system, the heating
apparatus is configured to provide heat sufficient to facilitate
homogeneously mixing the fluid food ingredient and the solid food
ingredient, and insufficient to cook the fluid food ingredient and
the solid food ingredient.
[0179] In one example of a food preparation system, the package is
flexible.
[0180] In one example of a food preparation system, the package is
disposable.
[0181] In one example of a food preparation system, the package is
reusable.
[0182] In one example, there is provided a method for preparing a
food product, comprising:
[0183] obtaining a package having a solid food ingredient disposed
therein;
[0184] introducing a fluid food ingredient and the solid food
ingredient to one another within the package;
[0185] mixing the fluid food ingredient and the solid food
ingredient to form a food mixture in the package; and
[0186] forming the food mixture into a predetermined shape within
the package.
[0187] In one example of a food product preparation method, the
solid food ingredient is contained within the package by a
frangible seal.
[0188] In one example of a food product preparation method, the
fluid food ingredient and the solid food ingredient are disposed in
the package in separate compartments of the package formed at least
in part by the frangible seal.
[0189] In one example of a food product preparation method,
introducing the fluid food ingredient and the solid food ingredient
to one another within the package comprises providing a pressurized
fluid to one of the compartments to break the frangible seal.
[0190] In one example of a food product preparation method, forming
the food mixture comprises applying pressure to the food
mixture.
[0191] In one example of a food product preparation method,
applying pressure to the food mixture comprises molding the food
mixture.
[0192] In one example of a food product preparation method, molding
the food mixture comprises compressing the food mixture with a die
into the predetermined shape.
[0193] In one example of a food product preparation method, mixing
the fluid food ingredient and the solid food ingredient to form the
food mixture in the package comprises shaking the fluid food
ingredient and the solid food ingredient.
[0194] In one example of a food product preparation method, the
method further comprises heating at least one of the fluid food
ingredient and the solid food ingredient.
[0195] In one example of a food product preparation method, heating
is sufficient to facilitate homogeneously mixing the fluid food
ingredient and the solid food ingredient, and insufficient to cook
the fluid food ingredient and the solid food ingredient.
[0196] In one example of a food product preparation method, the
fluid food ingredient is in a solid state prior to heating.
[0197] In one example of a food product preparation method, the
method further comprises drying the food mixture to remove moisture
from the food mixture.
[0198] In one example of a food product preparation method, wherein
drying the food mixture comprises moving air about the food
mixture.
[0199] In one example of a food product preparation method, drying
the food mixture comprises applying heat to the food mixture.
[0200] In one example of a food product preparation method, the
fluid food ingredient maintains the food mixture in the
predetermined shape upon cooling.
[0201] In one example of a food product preparation method, the
method further comprises applying a topping to the food mixture
formed in the predetermined shape.
[0202] In one example of a food product preparation method, the
solid food ingredient comprises a plurality of solid food
ingredients, and further comprising mixing the plurality of solid
food ingredients to form a homogeneous blend of solid food
ingredients.
[0203] In one example of a food product preparation method, the
package contains the food mixture until consumed (i.e. becomes the
wrapper for the finished food product).
[0204] In one example of a food product preparation method, the
package is flexible.
[0205] In one example of a food product preparation method, the
package is disposable.
[0206] In one example of a food product preparation method, a
volume ratio of the solid food ingredient to the fluid food
ingredient is between about 65:35 and about 95:5.
[0207] In one example of a food product preparation method, mixing
is completed in less than about three minutes.
[0208] Of course, it is to be understood that the above-described
arrangements are only illustrative of the application of the
principles of the present invention. Numerous modifications and
alternative arrangements may be devised by those skilled in the art
without departing from the spirit and scope of the present
invention and the appended claims are intended to cover such
modifications and arrangements. Thus, while the present invention
has been described above with particularity and detail in
connection with what is presently deemed to be the most practical
and preferred embodiments of the invention, it will be apparent to
those of ordinary skill in the art that numerous modifications,
including, but not limited to, variations in size, materials,
shape, form, function and manner of operation, assembly and use may
be made without departing from the principles and concepts set
forth herein.
* * * * *