U.S. patent application number 17/122757 was filed with the patent office on 2021-05-06 for system for providing a single serving of a frozen confection.
This patent application is currently assigned to Sigma Phase, Corp.. The applicant listed for this patent is Sigma Phase, Corp.. Invention is credited to Matthew Fonte.
Application Number | 20210127706 17/122757 |
Document ID | / |
Family ID | 1000005535222 |
Filed Date | 2021-05-06 |
United States Patent
Application |
20210127706 |
Kind Code |
A1 |
Fonte; Matthew |
May 6, 2021 |
SYSTEM FOR PROVIDING A SINGLE SERVING OF A FROZEN CONFECTION
Abstract
A system for providing a single serving of a frozen confection,
wherein the system comprises a pod comprising at least one
ingredient for providing a single serving of a frozen confection;
the system cools the pod; the system introduces water into the pod;
the system simultaneously stirs the contents of the pod while
scraping at least one wall of the pod to prevent a build-up of the
frozen confection on the at least one wall of the pod; and the
system ejects the frozen confection out of the pod.
Inventors: |
Fonte; Matthew; (Concord,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sigma Phase, Corp. |
Billerica |
MA |
US |
|
|
Assignee: |
Sigma Phase, Corp.
Billerica
MA
|
Family ID: |
1000005535222 |
Appl. No.: |
17/122757 |
Filed: |
December 15, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16889328 |
Jun 1, 2020 |
10897916 |
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17122757 |
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16588086 |
Sep 30, 2019 |
10667542 |
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16889328 |
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16360220 |
Mar 21, 2019 |
10426180 |
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16588086 |
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16104758 |
Aug 17, 2018 |
10334868 |
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16360220 |
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15625690 |
Jun 16, 2017 |
10358284 |
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16104758 |
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62616742 |
Jan 12, 2018 |
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62351001 |
Jun 16, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A23G 9/224 20130101;
A23G 9/22 20130101; B65D 51/32 20130101; A23G 9/28 20130101; B65D
85/8046 20130101; A23G 9/52 20130101; A23G 9/12 20130101 |
International
Class: |
A23G 9/22 20060101
A23G009/22; A23G 9/28 20060101 A23G009/28; A23G 9/12 20060101
A23G009/12; B65D 85/804 20060101 B65D085/804; B65D 51/32 20060101
B65D051/32; A23G 9/52 20060101 A23G009/52 |
Claims
1. A method for providing a single serving of a frozen confection
with an average diameter of ice crystals within the frozen
confection being less than or equal to 50 .mu.m in under 2 minutes,
the method comprising: inserting a pod containing one or more
ingredients and a mixing paddle into a recess of a machine for
providing the single serving of the frozen confection; contacting a
side wall of the pod against a side wall of the recess; connecting
a motor of the machine to the mixing paddle; rotating the mixing
paddle inside the pod while cooling the recess to form the frozen
confection from the one or more ingredients, wherein rotating the
mixing paddle comprises removing ice crystals from the sidewall of
the pod and increasing rotation of the mixing paddle from an
initial mixing speed to a higher mixing speed while freezing the
frozen confection; and moving the mixing paddle inside the pod to
dispense the frozen confection through an opening in an end wall of
the pod, wherein the frozen confection is dispensed directly from
the pod while the pod is in the recess of the machine.
2. The method of claim 1, wherein the higher mixing speed is 400
RPM.
3. The method of claim 1, wherein the rotation of the mixing paddle
is based on the viscosity of the frozen confection.
4. The method of claim 3, further comprising adjusting the
rotational speed of the mixing paddle in response to a changing
viscosity of the frozen confection.
5. The method of claim 3, further comprising slowing the rotation
of the mixing paddle in response to an increasing viscosity of the
frozen confection.
6. The method of claim 1, wherein removing the ice crystals from
the sidewall of the pod comprises scraping the ice crystals from
the sidewall of the pod.
7. The method of claim 6, wherein the scraping is performed
continuously.
8. A method for providing cooled food or drink with an average
diameter of ice crystals within the cooled food or drink being less
than or equal to 50 .mu.m in under 2 minutes, the method
comprising: inserting a pod into a recess of a machine for
providing the cooled food or drink, the pod containing one or more
ingredients and a paddle, the machine comprising a refrigerant to
cool the food or drink; contacting a sidewall of the pod against a
sidewall of the recess; connecting a motor of the machine to the
paddle by a shaft extending from a machine lid to the pod; rotating
the mixing paddle inside the pod to scrape the cooled food or drink
off a wall of the pod and mix the cooled food or drink by forcing
the flow of the contents through openings defined in blades of the
mixing paddle and increasing rotation of the mixing paddle from an
initial mixing speed to a higher mixing speed while freezing the
cooled food or drink; opening a seal of an opening defined in a
floor of the pod; and rotating the mixing paddle inside the pod in
a dispensing direction to force the contents of the pod through the
opening in the floor of the pod.
9. The method of claim 8, wherein the higher mixing speed is 400
RPM.
10. The method of claim 8, wherein the rotation of the mixing
paddle is based on the viscosity of the frozen confection.
11. The method of claim 10, further comprising adjusting the
rotational speed of the mixing paddle in response to a changing
viscosity of the frozen confection.
12. The method of claim 10, further comprising slowing the rotation
of the mixing paddle in response to an increasing viscosity of the
frozen confection.
13. The method of claim 10, wherein rotating the mixing paddle
inside the pod to scrape the cooled food or drink off a wall of the
pod is performed continuously.
14. A method for providing cooled food or drink and heated food or
drink with an average diameter of ice crystals within the cooled
food or drink being less than or equal to 50 .mu.m in under 2
minutes, the method comprising: inserting a first pod into a first
recess of a machine for providing the cooled food or drink, the
first pod containing one or more ingredients and a mixing paddle,
the machine comprising a refrigerant to cool the food or drink;
inserting a second pod into a second recess of a machine for
providing the heated food or drink, the second recess being
adjacent to the first recess, the second pod containing one or more
ingredients; contacting a side wall of the first pod against a side
wall of the first recess; connecting a motor of the machine to the
mixing paddle by a shaft; rotating the mixing paddle inside the
first pod in a mixing direction to scrape the cooled food or drink
of the side wall of the first pod and increasing rotation of the
mixing paddle from an initial mixing speed to a higher mixing speed
while freezing the cooled food or drink; opening a seal of an
opening defined in a floor of the first pod; and rotating the
mixing paddle inside the pod in a dispensing direction to force the
contents of the first pod through the opening in the floor of the
first pod.
15. The method of claim 14, wherein the higher mixing speed is 400
RPM.
16. The method of claim 14, wherein the rotation of the mixing
paddle is based on the viscosity of the frozen confection.
17. The method of claim 16, further comprising adjusting the
rotational speed of the mixing paddle in response to a changing
viscosity of the frozen confection.
18. The method of claim 16, further comprising slowing the rotation
of the mixing paddle in response to an increasing viscosity of the
frozen confection.
19. The method of claim 14, wherein rotating the mixing paddle
inside the first pod in the mixing direction to scrape the cooled
food or drink of the side wall of the first pod is performed
continuously.
20. The method of claim, 14, wherein increasing the rotation of the
mixing paddle from the initial mixing speed to the higher mixing
speed comprises changing the rotation of the mixing paddle from 5
RPM
Description
REFERENCE TO PENDING PRIOR PATENT APPLICATIONS
[0001] This patent application:
[0002] (1) is a continuation of pending prior U.S. patent
application Ser. No. 16/889,328, filed Jun. 1, 2020 by Sigma Phase,
Corp. and Matthew Fonte for SYSTEM FOR PROVIDING A SINGLE SERVING
OF A FROZEN CONFECTION, (Attorney's Docket No. 47354-0004004),
which patent application:
[0003] (2) is a continuation of pending prior U.S. patent
application Ser. No. 16/588,086, filed Sep. 30, 2019 by Sigma
Phase, Corp. and Matthew Fonte for SYSTEM FOR PROVIDING A SINGLE
SERVING OF A FROZEN CONFECTION, (Attorney's Docket No.
47354-0004003), which patent application:
[0004] (3) is a continuation of pending prior U.S. patent
application Ser. No. 16/360,220, filed Mar. 21, 2019 by Sigma
Phase, Corp. and Matthew Fonte for SYSTEM FOR PROVIDING A SINGLE
SERVING OF A FROZEN CONFECTION, (Attorney's Docket No.
47354-0004002), which patent application:
[0005] (4) is a continuation of pending prior U.S. patent
application Ser. No. 16/104,758, filed Aug. 17, 2018 now U.S. Pat.
No. 10,334,868, issued Jul. 2, 2019, by Sigma Phase, Corp. and
Matthew Fonte for SYSTEM FOR PROVIDING A SINGLE SERVING OF A FROZEN
CONFECTION, (Attorney's Docket No. 47354-0004001), which patent
application:
[0006] (5) is a continuation-in-part of pending prior U.S. patent
application Ser. No. 15/625,690, filed Jun. 16, 2017, now U.S. Pat.
No. 10,358,284, issued Jul. 23, 2019, by Sigma Phase, Corp. and
Matthew Fonte for SYSTEM FOR PROVIDING A SINGLE SERVING OF A FROZEN
CONFECTION (Attorney's Docket No. 47354-0003001), which patent
application: [0007] (a) claims benefit of prior U.S. Provisional
Patent Application Ser. No. 62/351,001, filed Jun. 16, 2016 by
Xciting Innovations, LLC for SINGLE SERVE ICE CREAM MACHINE:
COMPRESSOR, VORTEX TUBE, SPRAY NOZZLE, SINGLE POD OF DRY ICE CREAM
MIX (Attorney's Docket No. 47354-0003P01); and
[0008] (6) claims benefit of pending prior U.S. Provisional Patent
Application Ser. No. 62/616,742, filed Jan. 12, 2018 by Sigma
Phase, Corp. and Matthew Fonte for SYSTEM FOR PROVIDING A SINGLE
SERVING OF A FROZEN CONFECTION (Attorney's Docket No.
47354-0004P01).
[0009] The above-identified patent applications are hereby
incorporated herein by reference.
FIELD OF THE INVENTION
[0010] This invention relates generally to systems for providing a
frozen confection (e.g., "soft serve" or regular ("hard") ice
cream, frozen yogurt, frozen protein shakes, smoothies, etc.), and
more particularly to systems for providing a single serving of a
frozen confection.
BACKGROUND OF THE INVENTION
[0011] Current domestic ice cream makers are generally designed to
produce relatively large batches of ice cream, typically ranging
from 1.0 liter to 2.0 liters or more, in a time period of
approximately 20-60 minutes. In addition, most current domestic ice
cream makers also require that the containers (within which the ice
cream will be produced) be "frozen" before making the ice cream,
i.e., the container must be placed in a freezer for approximately
4-8 hours before use. Thus, there is a substantial delay between
the time that the making of the ice cream commences and the time
that the batch of ice cream is completed. Furthermore, even after
the batch of ice cream has been completed, it is still necessary to
manually remove the ice cream from the ice cream maker, and then it
is also necessary to scoop out single servings of the ice cream
into a separate container (e.g., a bowl, a cone, etc.) for
consumption.
[0012] Thus there is a need for a new system for providing a single
serving of a frozen confection, in a reduced period of time, and
which is dispensed directly into the container (e.g., a bowl, a
cone, etc.) from which it will be consumed.
[0013] In addition, it would also be desirable for the same system
to be capable of providing a single serving of a cold beverage,
and/or a single serving of a hot beverage.
SUMMARY OF THE INVENTION
[0014] The present invention comprises the provision and use of a
novel system for providing a single serving of a frozen confection,
in a reduced period of time, and which is dispensed directly into
the container (e.g., a bowl, a cone, etc.) from which it will be
consumed. The novel system is small enough to fit onto kitchen
countertops, fit underneath kitchen cabinets (which are typically
18 inches in height or less), be powered by 120 volt kitchen
electric wall sockets with a maximum of 1800 watts, and weigh less
than 50 lbs. The novel system is capable of making at least 5 fluid
ounces of frozen confection in approximately 5 minutes or less and
is capable of producing at least 4 batches of frozen confection
sequentially without any lag time between the batches.
[0015] In addition, the same system is also capable of providing a
single serving of a cold beverage, and/or a single serving of a hot
beverage.
[0016] In one preferred form of the invention, there is provided
apparatus for providing a single serving of an ingestible
substance, the apparatus comprising:
[0017] a nest for receiving a pod containing at least one
ingredient for forming a single serving of the ingestible
substance, wherein the nest comprises an annular recess for
receiving a pod having an annular configuration;
[0018] a cooling unit for cooling the pod; and
[0019] a water supply for introducing water into the pod.
[0020] In another preferred form of the invention, there is
provided apparatus for providing and dispensing a single serving of
a ingestible substance, the apparatus comprising:
[0021] a nest for receiving a pod containing at least one
ingredient for forming a single serving of the ingestible
substance, wherein the pod comprises at least one internal
paddle;
[0022] a cooling unit for cooling the pod;
[0023] a water supply for introducing water into the pod; and
[0024] a rotation unit for rotating the at least one internal
paddle of the pod.
[0025] In another preferred form of the invention, there is
provided apparatus for providing a single serving of an ingestible
substance, the apparatus comprising:
[0026] a nest for receiving a pod containing at least one
ingredient for forming a single serving of the ingestible
substance;
[0027] a heat transfer unit for transferring heat between the pod
and the nest, wherein the heat transfer unit is capable of (i)
taking heat out of the pod, and (ii) supplying heat to the pod;
and
[0028] a water supply for introducing water into the pod.
[0029] In another preferred form of the invention, there is
provided a method for providing a single serving of a frozen
confection, the method comprising:
[0030] providing a pod comprising at least one ingredient for
providing a single serving of a frozen confection;
[0031] cooling the pod;
[0032] introducing water into the pod;
[0033] simultaneously stirring the contents of the pod while
scraping at least one wall of the pod to prevent a build-up of the
frozen confection on the at least one wall of the pod; and
[0034] ejecting the frozen confection out of the pod.
[0035] In another preferred form of the invention, there is
provided a pod for providing a single serving of an ingestible
substance, the pod comprising:
[0036] a sealed container comprising: [0037] at least one
ingredient disposed within the sealed container for forming a
single serving of the ingestible substance; and [0038] at least one
paddle disposed within the sealed container for agitating the at
least one ingredient.
[0039] In still other forms of the invention, novel systems are
disclosed for providing a single serving of a frozen
confection.
[0040] And in still other forms of the invention, novel pods are
disclosed for providing a single serving of a frozen
confection.
[0041] In another form of the invention, there is provided a method
for providing a single serving of ice cream, said method
comprising:
[0042] providing: [0043] a pod comprising: [0044] a tapered body
having a smaller first end, a larger second end and a side wall
extending therebetween, said tapered body defining an interior;
[0045] a cap permanently mounted to said larger second end of said
tapered body; [0046] a scraper mixing paddle movably disposed
within said interior of said tapered body, said scraper mixing
paddle comprising a blade; [0047] an exit port formed in said first
end of said tapered body and communicating with said interior of
said tapered body; and [0048] an ingredient for providing a single
serving of ice cream when cooled; and [0049] a nest comprising a
tapered cavity having a smaller first end, a larger second end and
a side wall extending therebetween;
[0050] inserting said pod into said second end of said tapered
cavity of said nest and causing said side wall of said tapered body
of said pod to seat substantially flush against said side wall of
said tapered cavity of said nest;
[0051] cooling said nest and rotating said scraper mixing paddle so
as to stir said ingredient as said ingredient is converted into ice
cream, with said blade of said scraper mixing paddle contacting,
and riding against and scraping, said side wall of said pod;
[0052] opening said exit port; and
[0053] dispensing said ice cream from said pod through said exit
port.
BRIEF DESCRIPTION OF THE DRAWINGS
[0054] These and other objects and features of the present
invention will be more fully disclosed or rendered obvious by the
following detailed description of the preferred embodiments of the
invention, which is to be considered together with the accompanying
drawings wherein like numbers refer to like parts, and further
wherein:
[0055] FIGS. 1-6 are schematic views showing a novel system for
providing a single serving of a frozen confection, wherein all of
the components of the system are shown in FIGS. 1-3 as being opaque
and wherein some of the components of the system are shown in FIGS.
4-6 as being transparent;
[0056] FIGS. 7-12 are schematic views showing further details of
the nest assembly of the system shown in FIGS. 1-6;
[0057] FIGS. 13 and 14 are schematic views showing further details
of (i) the lid assembly of the system shown in FIGS. 1-6, (ii)
portions of the cold water and air delivery assembly of the system
shown in FIGS. 1-6, and (iii) the control electronics of the system
shown in FIGS. 1-6;
[0058] FIGS. 15 and 16 are schematic views showing, among other
things, further details of the heat dissipation assembly of the
system shown in FIGS. 1-6;
[0059] FIG. 17 is a schematic view showing further details of the
control electronics of the system shown in FIGS. 1-6;
[0060] FIGS. 18-20 are schematic views showing further details of
the pod of the system shown in FIGS. 1-6;
[0061] FIG. 21 is a schematic view showing exemplary operation of
the system shown in FIGS. 1-6;
[0062] FIGS. 22 and 23 are schematic views showing alternative
approaches for cooling the inner portion of the nest assembly of
the system shown in FIGS. 1-6;
[0063] FIGS. 24-27 are schematic views showing another pod which
may be used with the system shown in FIGS. 1-6;
[0064] FIG. 28 is a schematic view showing another novel system for
providing a single serving of a frozen confection;
[0065] FIGS. 29-31 are schematic views showing another novel system
for providing a single serving of a frozen confection;
[0066] FIGS. 32-35 are schematic views showing another novel system
formed in accordance with the present invention, wherein the novel
system comprises a compressor-cooled machine with a fixed-cap
pod;
[0067] FIG. 35A is a schematic view showing another novel system
formed in accordance with the present invention, wherein the novel
system comprises a pair of nests for producing a desired cold
confection or a desired hot or cold beverage;
[0068] FIGS. 35B and 35C are schematic views showing additional
nest and pod configurations formed in accordance with the present
invention;
[0069] FIG. 36 is a graph showing the eutectic point of a eutectic
solution;
[0070] FIG. 37 is a schematic view showing a coaxial tube for
delivering the refrigerant driven by the compressor with enhanced
efficiency;
[0071] FIG. 37A is a schematic view showing one preferred
arrangement for cooling a pod disposed in the nest;
[0072] FIG. 38 is a schematic view showing a direct expansion
system which may be used to cool the nest assembly;
[0073] FIG. 38A is a schematic view showing another preferred
arrangement for cooling a pod disposed in the nest;
[0074] FIGS. 39-42 are schematic views showing another form of pod
which may be used with the present invention;
[0075] FIG. 42A is a schematic view showing another form of pod
which may be used with the present invention;
[0076] FIG. 42B is a schematic view showing movement of the
contents of the pod during mixing;
[0077] FIG. 43 is a schematic view showing how the nest assembly
may comprise a flexible bladder for receiving a pod, such that the
flexible bladder makes a close fit with a pod disposed in the nest
assembly; and
[0078] FIG. 44 is a schematic view showing "bubble beads" contained
in the ingredients disposed within a pod, wherein the encapsulant
is selected so that when water is added to the interior of the pod,
the encapsulant dissolves, releasing the CO.sub.2 or N.sub.2 and
creating a "fizz" in the frozen confection.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0079] The present invention comprises the provision and use of a
novel system for providing a single serving of a frozen confection,
in a reduced period of time, and which is dispensed directly into
the container (e.g., a bowl, a cone, etc.) from which it will be
consumed.
[0080] In addition, the same system is also capable of providing a
single serving of a cold beverage, and/or a single serving of a hot
beverage.
The System in General
[0081] In one preferred form of the invention, and looking first at
FIGS. 1-6, there is provided a novel system 10 for providing a
single serving of a frozen confection (e.g., ice cream, frozen
yogurt, a smoothie, etc.). System 10 is also capable of providing a
single serving of a cold beverage, and/or a single serving of a hot
beverage.
[0082] For clarity of explanation, system 10 will first be
described in the context of providing a single serving of a frozen
confection; then system 10 will be described in the context of
providing a single serving of a cold beverage; and then system 10
will be described in the context of providing a single serving of a
hot beverage.
[0083] System 10 generally comprises a machine 20 and a pod 30,
wherein machine 20 is configured to, among other things, receive a
pod 30 containing a supply of ingredients for forming a single
serving of the frozen confection, cool pod 30 (and its contents),
introduce cold water and air into pod 30, agitate the contents of
pod 30 so as to form the frozen confection, and then eject the
frozen confection from pod 30 directly into the container (e.g., a
bowl, a cone, etc.) from which it will be consumed.
[0084] The Machine
[0085] Machine 20 is configured to, among other things, receive a
pod 30 containing a supply of ingredients for forming a single
serving of the frozen confection, cool pod 30 (and its contents),
introduce cold water and air into pod 30, agitate the contents of
pod 30 so as to form the frozen confection, and then eject the
frozen confection from pod 30 directly into the container (e.g., a
bowl, a cone, etc.) from which it will be consumed.
[0086] To this end, machine 20 is a reusable device which generally
comprises a housing 40, a nest assembly 50, a lid assembly 60, a
water supply 70, a cold water and air delivery assembly 80, a heat
dissipation assembly 90 and control electronics 100.
[0087] Housing 40 is shown in FIGS. 1-6. Housing 40 generally
comprises a base 110, a cover 120 mounted to base 110, and a tray
130 mounted to base 110. Cover 120 serves to enclose interior
components of machine 20 and to support other components of machine
20. Tray 130 serves to receive a container (e.g., a bowl) into
which the frozen confection is to be ejected and from which the
frozen confection is to be consumed (alternatively, where the
frozen confection is to be consumed from a cone, the cone is held
above tray 130). If desired, a cooling element (e.g., a
thermoelectric (TEC) assembly comprising a thermoelectric cooler
(TEC) element) may be disposed in the base of tray 130 so that tray
130 can "pre-cool" a container (e.g., a bowl) which is to receive
the frozen confection.
[0088] Nest assembly 50 is shown in further detail in FIGS. 7-12.
Nest assembly 50 serves to receive a pod 30 containing a supply of
ingredients for forming a single serving of the frozen confection
and, among other things, rapidly cool pod 30 (and its contents) so
as to provide a single serving of a frozen confection in a reduced
period of time. To this end, and as will hereinafter be discussed,
nest assembly 50 and pod 30 are each provided with a unique
configuration and a unique construction so as to speed up cooling
of pod 30.
[0089] More particularly, nest assembly 50 generally comprises a
nest 140 having a top surface 150, a bottom surface 160 and a
plurality of outer faces 170. In one preferred form of the
invention, nest 140 has eight outer faces 170, so that nest 140 has
a generally octagonal configuration. Alternatively, nest 140 may
have a different number of outer faces 170. Nest 140 is preferably
formed out of a high heat-transfer material such as aluminum.
[0090] Nest 140 also comprises a bore 180 and a counterbore 190. A
hollow cylinder 200 is disposed in bore 180 and extends upward into
counterbore 190. As a result of this construction, an annular
recess 210 (i.e., a toroidal recess 210) is formed in top surface
150 of nest 140. Annular recess 210 is generally characterized by
an outer wall 220 (which is defined by the aforementioned
counterbore 190) and an inner wall 230 (which is defined by the
aforementioned hollow cylinder 200). Annular recess 210 is sized to
receive pod 30 therein as will hereinafter be discussed.
[0091] Nest 140 also comprises a bore 232 which opens on bottom
surface 160 of nest 140 and communicates with the interior of
annular recess 210. An exit nozzle 233 is mounted to bottom surface
160 of nest 140 at bore 232 so that exit port 234 of exit nozzle
233 communicates with the interior of annular recess 210. A pod
sensor 235 is provided in nest 140 to detect when a pod 30 is
disposed in annular recess 210 of nest 140.
[0092] Nest assembly 50 also comprises a plurality of
thermoelectric (TEC) assemblies 240. TEC assemblies 240 each
comprise a thermoelectric cooler (TEC) element 250, a heat sink 260
and a plurality of heat pipes 270 extending between TEC element 250
and heat sink 260 so as to transfer heat from TEC element 250 to
heat sink 260. If desired, multiple TEC elements 250 can be stacked
on each heat sink 260 so as to achieve higher temperature
differences than can be had with single-stage TEC elements 250. As
seen in FIGS. 7, 8 and 11, TEC assemblies 240 are positioned
against outer faces 170 of nest 140 so that TEC elements 250 can
provide cold or heat to outer faces 170 of nest 140, depending on
the direction of the electric current flow supplied to TEC elements
250, whereby to provide cold or heat to outer wall 220 of annular
recess 210 of nest 140 (and hence to provide cold or heat to a pod
30 disposed in annular recess 210 of nest 140). It will be
appreciated that when machine 20 is to be used to provide a frozen
confection, the direction of the electric current flow supplied to
TEC elements 250 causes cold to be applied to outer faces 170 of
nest 140.
[0093] Heat pipes 270 are preferably of the sort shown in FIG. 12,
i.e., they provide a high heat-transfer capacity for transferring
heat from TEC elements 250 to heat sinks 260. Heat pipes 270 are
preferably also connected to heat dissipation assembly 90 so as to
carry the heat collected by heat pipes 270 to heat dissipation
assembly 90 for further dissipation to the environment.
[0094] Nest assembly 50 also comprises a cylindrical TEC 280 for
providing cold to inner wall 230 of annular recess 210, and a
cylindrical TEC 290 for supplying heat to inner wall 230 of annular
recess 210.
[0095] Lid assembly 60 is shown in further detail in FIGS. 13 and
14. Lid assembly 60 generally comprises a handle 300 to which is
mounted a lid 310, such that lid 310 moves in conjunction with
handle 300. Handle 300 is pivotally mounted to cover 120 of housing
40 via a pivot pin 320. As a result of this construction, lid
assembly 60 can pivot towards or away from nest assembly 50 (see
FIG. 1). A lid sensor 325 (FIGS. 1 and 2) is provided for detecting
when lid 310 is in its closed position.
[0096] Lid assembly 60 comprises a plunger 330 which is movably
mounted to lid 310. More particularly, plunger 330 comprises a
circumferential gear 340 and a longitudinal gear 350, and lid
assembly 60 comprises a rotation motor 360 for driving a rotation
gear 370 and a vertical motor 380 for driving a vertical gear 390,
with rotation gear 370 of rotation motor 360 engaging
circumferential gear 340 of plunger 330, and with vertical gear 390
of vertical motor 380 engaging longitudinal gear 350 of plunger
330. As a result of this construction, rotation motor 360 can cause
plunger 330 to rotate within lid 310, and vertical motor 380 can
cause plunger 330 to move vertically within lid 310.
[0097] Plunger 330 further comprises a plurality of fingers 400 for
engaging counterpart fingers on pod 30 (see below), and a pair of
hollow fangs 410, 420 for penetrating the top of pod 30 and
delivering additional ingredients into pod 30 (see below).
[0098] Looking next at FIGS. 1-6, water supply 70 generally
comprises an ambient-temperature water tank 430 and a cold water
tank 440. In one preferred form of the invention,
ambient-temperature water tank 430 may hold approximately 2.0
liters of water, and cold water tank 440 may hold approximately 0.5
liter of water. Ambient-temperature water tank 430 comprises a
removable cover 445 to enable ambient-temperature water tank 430 to
be filled with water. A line (not shown) is provided for moving
water from ambient-temperature water tank 430 to cold water tank
440. A water sensor 450 (FIG. 4) is provided for monitoring for the
presence of water in ambient-temperature water tank 430, and a
water temperature sensor 460 (FIG. 6) is provided for monitoring
the temperature of the water in cold water tank 440. A plurality of
TEC assemblies 470, each preferably similar to the aforementioned
TEC assemblies 240, are provided for chilling the water in cold
water tank 440, i.e., TEC assemblies 470 comprise TEC elements 473,
heat sinks 475 and heat pipes 477. Heat pipes 477 of TEC assemblies
470 are preferably connected to heat dissipation assembly 90 so as
to carry the heat produced by TEC assemblies 470 to heat
dissipation assembly 90.
[0099] Looking next at FIGS. 6 and 14, cold water and air delivery
assembly 80 generally comprises a water pump 480 which pumps cold
water from cold water tank 440 into hollow fang 410 of plunger 330,
and an air pump 490 which pumps air into hollow fang 420 of plunger
330. In one preferred form of the invention, hollow fang 410
comprises a spray nozzle for injecting droplets of atomized water
into pod 30 (see below), whereby to facilitate the formation of the
frozen confection (see below). Such spray nozzles are well known in
the art of liquid dispersion. Cold water and air delivery assembly
80 also comprises various fluid lines (not shown) for transferring
water from cold water tank 440 to hollow fang 410 of plunger 330
and for introducing air into hollow fang 420 of plunger 330.
[0100] Heat dissipation assembly 90 is shown in further detail in
FIGS. 15 and 16. Heat dissipation assembly 90 dissipates heat
received from heat pipes 270 of TEC assemblies 240 of nest 140 and
dissipates heat received from the heat pipes 477 of TEC assemblies
470 of cold water tank 440. Heat dissipation assembly 90 generally
comprises a plurality of heat sinks 500 which draw heat from heat
pipes 510 (which are connected to heat pipes 270 of TEC assemblies
240 of nest 140 and heat pipes 477 of TEC assemblies 470 of cold
water tank 440), a plurality of condensers 520 for receiving heat
from heat sinks 500, and a plurality of fans 530 for cooling
condensers 520.
[0101] Control electronics 100 generally comprise a power supply
540 (FIG. 14), a central processing unit (CPU) 550 and a user
interface 570 (FIG. 2), e.g., a display screen, operating buttons,
etc. As seen in FIG. 17, power supply 540 and CPU 550 are connected
to the aforementioned water sensor 450, water temperature sensor
460, TEC assemblies 470, cylindrical TEC 280, cylindrical TEC 290,
lid sensor 325, pod sensor 235, TEC assemblies 240, water pump 480,
air pump 490, rotation motor 360, vertical motor 380, condensers
520, fans 530 and user interface 570. CPU 550 is appropriately
programmed to operate machine 20 in response to instructions
received from user interface 570 as will hereinafter be
discussed.
[0102] It will be appreciated that machine 20 is preferably
configured to operate at a maximum load of 1800 watts, which is
generally the maximum load that standard outlets in a kitchen can
handle.
[0103] The Pod Pod 30 contains a supply of ingredients for
providing a single serving of a frozen confection (e.g., ice cream,
frozen yogurt, a smoothie, etc.). In the preferred form of the
invention, pod 30 is provided as a single-use, disposable pod,
i.e., a new pod 30 is used for each serving of the frozen
confection.
[0104] As noted above, and as will hereinafter be discussed, pod 30
is provided with a unique configuration and a unique construction
so as to speed up cooling of pod 30 (and its contents), whereby to
speed up the process of producing the frozen confection.
[0105] More particularly, and looking now at FIGS. 18-20, pod 30
generally comprises a base 580 having an opening 590 formed
therein. An outer hollow tube 600 rises upward from the outer
perimeter of base 580, and an inner hollow tube 610 is disposed in
opening 590 of base 580 and rises upward from the inner perimeter
of base 580. As a result of this construction, an annular recess
620 (i.e., a toroidal recess 620) is formed between base 580, outer
hollow tube 600 and inner hollow tube 610, with annular recess 620
being generally characterized by a floor 630 (defined by base 580),
an outer wall 640 (defined by outer hollow tube 600) and an inner
wall 650 (defined by inner hollow tube 610). Note that the diameter
of outer hollow tube 600 of pod 30 is slightly less than the
diameter of counterbore 190 of nest 140, and the diameter of inner
hollow tube 610 of pod 30 is slightly greater than the diameter of
hollow cylinder 200 of nest assembly 50, such that pod 30 can be
seated in annular recess 210 of nest 140, with outer hollow tube
600 of pod 30 making a close sliding fit with outer wall 220 of
nest 140 and with inner hollow tube 610 of pod 30 making a close
sliding fit with inner wall 230 of nest assembly 50.
[0106] Preferably base 580 of pod 30 comprises a high heat-transfer
material (e.g., aluminum, a molded polymer, etc.), outer hollow
tube 600 of pod 30 comprises a high heat-transfer material (e.g.,
aluminum, a molded polymer, etc.) and inner hollow tube 610 of pod
30 comprises a high heat-transfer material (e.g., aluminum, a
molded polymer, etc.). In one preferred form of the invention, base
580, outer hollow tube 600 and inner hollow tube 610 comprise a
plastic/thin metallic film composite (i.e., a body of plastic
having an external covering of a thin metallic film). It should be
appreciated that the plastic/thin metallic film composite allows
for improved thermal transfer and helps preserve the contents of
pod 30, while also providing pod 30 with a unique packaging
appearance. Preferably base 580, outer hollow tube 600 and inner
hollow tube 610 are substantially rigid.
[0107] Thus it will be seen that, due to the unique configurations
and unique constructions of nest assembly 50 and pod 30, when a pod
30 is disposed in the annular recess 210 of nest 140, cold can be
efficiently applied to outer wall 640 of pod 30 by outer wall 220
of nest 140, cold can be efficiently applied to inner wall 650 of
pod 30 by inner wall 230 of nest assembly 50, and cold can be
efficiently applied to base 580 of pod 30 by the floor of annular
recess 210 of nest 140. As a result, machine 20 can rapidly cool
pod 30 (and its contents) so as to provide a single serving of a
frozen confection in a reduced period of time.
[0108] Pod 30 also comprises a cap 660, an outer helical scraper
paddle 670, an inner helical scraper paddle 680, and a bottom
scraper paddle 690.
[0109] Cap 660 has an outer edge 700 which is sized slightly
smaller than the diameter of outer wall 640 of pod 30, and cap 660
has an inner hole 710 which has a diameter slightly larger than
inner hollow tube 610 of pod 30, such that cap 660 can move
longitudinally into, and then along, annular recess 620 of pod 30
(see below). Cap 660 is preferably substantially rigid.
[0110] Cap 660 also comprises fingers 720 for engaging counterpart
fingers 400 of plunger 330, whereby rotational and longitudinal
motion can be imparted to cap 660 of pod 30 by plunger 330, as will
hereinafter be discussed. Cap 660 also comprises two weakened
portions 730, 740 for penetration by hollow fangs 410, 420,
respectively, of plunger 330, as will hereinafter be discussed in
further detail.
[0111] Outer helical scraper paddle 670 extends between cap 660 and
bottom scraper paddle 690, and comprises an outer edge 750 which
makes a close sliding fit with outer wall 640 of annular recess
620. Inner helical scraper paddle 680 extends between cap 660 and
bottom scraper paddle 690, and comprises an inner edge 760 which
makes a close sliding fit with inner hollow tube 610 of pod 30.
Bottom scraper paddle 690 comprises an outer ring 770 which
contacts base 580 and makes a close sliding fit with outer wall 640
of annular recess 620, an inner ring 780 which contacts base 580
and makes a close sliding fit with inner hollow tube 610 of pod 30,
and a pair of struts 790 which contact base 580 and extend between
outer ring 770 and inner ring 780. As a result of this
construction, fingers 720 may be used to turn cap 660 rotationally,
such that outer helical scraper paddle 670 rotates, scrapping the
interior surface of outer wall 640 of pod 30, inner helical scraper
paddle 680 rotates, scraping the exterior surface of inner hollow
tube 610, and struts 770 rotate, scraping floor 630 of base 580. It
will be appreciated that the provision of outer helical scraper
paddle 670, inner helical scraper paddle 680 and bottom scraper
paddle 690 is highly advantageous, since outer helical scraper
paddle 670, inner helical scraper paddle 680 and bottom scraper
paddle 690 can simultaneously (i) agitate the contents of pod 30 so
as to ensure uniform and rapid formation of the frozen confection,
and (ii) prevent the build-up of frozen confection on base 580,
outer hollow tube 600 and inner hollow tube 610, which could
inhibit cooling of the contents of pod 30.
[0112] Outer helical scraper paddle 670 and inner helical scraper
paddle 680 are configured and constructed so that they may be
longitudinally compressed by applying a longitudinal force to cap
660, whereby to move cap 660 into, and along, annular recess 620 of
pod 30, so as to bring cap 660 substantially into engagement with
base 580 (see below). In one preferred form of the invention, outer
helical scraper paddle 670 and inner helical scraper paddle 680 are
made out of spring steel, with outer helical scrapper paddle 670
and inner helical scraper paddle 680 compressing to substantially
flat configurations when a longitudinal force drives cap 660
against base 580 (or, more precisely, substantially against base
580, since the flattened outer helical scraper paddle 670 and the
flattened inner helical scraper paddle 680 will be disposed
between, and slightly separate, cap 660 from base 580). Bottom
scraper paddle 690 may also be formed out of spring steel. In
another preferred form of the invention, outer helical scraper
paddle 670 and/or inner helical scraper paddle 680 (and/or bottom
scraper paddle 690) may be made out of a plastic. If desired, outer
helical scraper paddle 670 and/or inner helical scraper paddle 680
(and/or bottom scraper paddle 690) may comprise a shape memory
material (e.g., Nitinol).
[0113] A bore 800 passes through base 580 and communicates with the
interior of annular recess 620. A weakened portion 810 normally
closes off bore 800 but may be ruptured upon the application of an
appropriate force so as to pass material (e.g., frozen confection)
therethrough. An exit nozzle 820 is mounted to base 580 adjacent to
bore 800 so that exit port 830 of exit nozzle 820 communicates with
the interior of annular recess 620 when weakened portion 810 has
been ruptured.
[0114] Pod 30 generally has a surface area-to-volume ratio which is
greater than 2:1, and which is preferably approximately 8:1. It
will be appreciated that increasing the surface area of pod 30
increases the speed of forming the frozen confection in pod 30,
since it allows heat to be drawn out of pod 30 (and its contents)
more quickly. It will also be appreciated that forming pod 30 with
a toroidal configuration (i.e., with both interior and exterior
access surfaces) provides increased surface area and enables more
rapid cooling of pod 30 and its contents, inasmuch as cold may be
simultaneously applied to both the outer surfaces of pod 30 and the
inner surfaces of pod 30.
[0115] By way of example but not limitation, in one preferred form
of the invention, pod 30 has an outer diameter of 2.25 inches and a
height of 3.75 inches (i.e., outer hollow tube 600 has an outer
diameter of 2.25 inches and a height of 3.75 inches), whereby to
provide a surface area of 26.49 square inches and a volume of 14.90
cubic inches; and pod 30 has an inner diameter of 1.4 inches and a
height of 3.75 inches (i.e., inner hollow tube 610 has an inner
diameter of 1.4 inches and a height of 3.75 inches), whereby to
provide a surface area of 16.49 square inches and a volume of 5.77
cubic inches; thereby yielding a total pod surface area of 42.98
square inches (i.e., 26.49 square inches+16.49 square inches=42.98
square inches) and a total pod volume of 9.13 cubic inches (i.e.,
14.90 cubic inches-5.77 cubic inches=9.13 cubic inches), and a
surface area-to-volume ratio of 8.47:1.
[0116] Pod 30 contains a fresh supply of ingredients for forming
the frozen confection (e.g., ice cream, frozen yogurt, smoothie,
etc.). More particularly, pod 30 may contain a frozen confection
mix (dry or liquid) containing, for example, sugar and powder
crystals, preferably many of which are less than 50 .mu.m in size,
and preferably containing at least 0.1% stabilizers by volume. A
dry frozen confection mix preferably has at least 50% of its
constituents (e.g., the sugar and powder crystals) having a size of
50 .mu.m or less.
[0117] Where pod 30 is to produce a single serving of ice cream, in
a preferred form of the invention, pod 30 may hold approximately
4-6 ounces of ingredients, and the ingredients may comprise
approximately 8% fat (e.g., cream, butter, anhydrous milk fat,
vegetable fat, etc.), approximately 1% milk solids-non-fat (MSNF)
(e.g., skim milk power (SMP), whole milk powder (WMP), evaporated
milk, condensed milk, etc.), approximately 13% sucrose,
approximately 0.5% emulsifier and approximately 0.5%
stabilizer.
[0118] By way of further example but not limitation, if pod 30
contains 1.25 ounces of dry yogurt mix, 5 ounces of frozen yogurt
will be formed in pod 30 after running machine 20.
Use of the System
[0119] Looking now at FIG. 21, machine 20 is prepared for use by
introducing water into ambient-temperature water tank 430 and
turning on machine 20. Water sensor 450 confirms that there is
water in ambient-temperature water tank 430. Machine 20 then pumps
water from ambient-temperature water tank 430 into cold water tank
440 and chills the water in cold water tank 440 using TEC
assemblies 470. Water temperature sensor 460 monitors the
temperature of the water in cold water tank 440. Preferably the
water in cold water tank 440 is cooled to between approximately 1-3
degrees C. Machine 20 then sits in this standby condition,
re-cooling the water in cold water tank 440 as needed, until a
single serving of a frozen confection (e.g., ice cream, frozen
yogurt, smoothie, etc.) is to be prepared.
[0120] When a single serving of a frozen confection is to be
prepared, lid assembly 60 of machine 20 is opened and a fresh pod
30 is positioned in annular recess 210 of nest 140. This is done so
that exit nozzle 820 of pod 30 seats in exit nozzle 233 of nest
140. Then lid assembly 60 is closed so that fingers 400 of plunger
330 engage fingers 720 of pod 30, and so that hollow fangs 410, 420
of plunger 330 penetrate the two weakened portions 730, 740 of pod
30. In addition, a container (i.e., the container from which the
frozen confection will be consumed) is placed on tray 130 of
machine 20, with the container being centered below exit nozzle 233
of nest assembly 50 (alternatively, where the frozen confection is
to be consumed from a cone, the cone is held above tray 130).
[0121] When pod sensor 235 senses the presence of a pod 30 in
annular recess 210 of nest 140, machine 20 cools nest assembly 50
via TEC assemblies 240 and cylindrical TEC 280, which in turn cools
the pod 30 (and its contents) which is located in annular recess
210 of nest 140. Note that TEC assemblies 240 cool the outer faces
170 of nest 140 so as to cool outer wall 220 of annular recess 210,
whereby to cool hollow outer tube 600 of pod 30, and cylindrical
TEC 280 cools hollow cylinder 200 so as to cool inner wall 230 of
annular recess 210, whereby to cool hollow inner tube 610 of pod
30. Note that the high surface area-to-volume ratio of pod 30,
provided by its toroidal configuration, allows for faster cooling
of the pod 30 (and its contents). By way of example but not
limitation, the contents of pod 30 can be cooled to a temperature
of approximately -30 degrees C. so as to form ice cream within 2
minutes (the contents of pod 30 will turn to ice cream at a
temperature of -18 degrees C., a lower temperature will produce ice
cream even faster). Note also that the heat removed from pod 30 via
TEC assemblies 240 and cylindrical TEC 280 is transferred to heat
dissipation assembly 90 for dissipation to the environment.
[0122] When pod 30 has been appropriately cooled, water pump 480
pumps an appropriate amount of cold water (e.g., at least 1.25
ounces of cold water) from cold water tank 440 into hollow fang 410
in plunger 330, and then through weakened portion 730 in cap 660,
so that the cold water is sprayed into the interior of pod 30 and
mixes with the contents of pod 30. In a preferred form of the
invention, 4 ounces of water at 2 degrees C. is sprayed into pod
30. At the same time, rotation motor 360 rotates plunger 330,
whereby to rotate cap 660 of pod 30, which causes outer helical
scraper paddle 670, inner helical scraper paddle 680 and bottom
scraper paddle 690 to rotate within annular recess 620 of pod
30.
[0123] Note that only cap 660, outer helical scraper paddle 670,
inner helical scraper paddle 680 and bottom scraper paddle 690
rotate, and the remainder of pod 30 remains stationary, inasmuch as
exit nozzle 820 of pod 30 is disposed in exit nozzle 233 of nest
assembly 50.
[0124] This rotational action agitates the contents of pod 30 so as
to ensure uniform and rapid mixing of the contents of pod 30. The
rotational speed of the scrapper paddles can change from
approximately 5 to approximately 400 RPM depending on the viscosity
of the frozen confection. In one preferred form of the invention, a
torque sensor is provided which adjusts the rotational speed of the
scraper paddles in response to the changing viscosity of the frozen
confection in pod 30 (e.g., the rotational speed of the scraper
paddles slows with the increasing viscosity of the frozen
confection). In addition, this rotational action causes outer
helical scraper paddle 670, inner helical scraper paddle 680 and
bottom scraper paddle 690 to continuously scrape the walls of pod
30 so as to prevent the build-up of frozen confection on the walls
of pod 30 (which could inhibit cooling of the contents of pod 30).
Then air pump 490 pumps air into hollow fang 420 in plunger 330,
and then through weakened portion 740 in cap 660, so that the air
enters the interior of pod 30 and mixes with the contents of pod
30. Preferably enough air is pumped into pod 30 to provide an
approximately 30%-50% overrun (i.e., air bubbles) in pod 30,
whereby to give the ice cream the desired "loft". As this occurs,
outer helical scraper paddle 670, inner helical scraper paddle 680
and bottom scraper paddle 690 continue to agitate the contents of
pod 30 so as to ensure uniform and rapid mixing of the contents of
pod 30 and so as to continuously scrape the walls of pod 30,
whereby to prevent a build-up of frozen confection on the walls of
pod 30 (which could inhibit cooling of the contents of pod 30).
[0125] In order to create a "smooth" frozen confection, the
majority of ice crystals formed in the frozen confection should be
smaller than approximately 50 .mu.m. If many of the ice crystals
are larger than 50 .mu.m, or if there are extremely large ice
crystals (i.e., over 100 .mu.m) present, the frozen confection will
be "coarse". System 10 is designed to produce a "smooth" frozen
confection by providing a majority of ice crystals smaller than
approximately 50 .mu.m.
[0126] More particularly, to develop ice crystals with the proper
dispersion (number, size and shape), it is necessary to control the
freezing process: rates of nucleation vs. growth of crystals.
System 10 does this by simultaneously scraping the inner and outer
surfaces of annular recess 620 of pod 30. In addition, in order to
generate numerous small ice crystals, the freezing conditions
within pod 30 must promote nuclei formation and minimize ice
crystal growth. Promoting ice nucleation requires very low
temperatures, e.g., ideally as low as -30 degrees C., in order to
promote rapid nucleation. System 10 freezes the contents of pod 30
very quickly (e.g., under 2 minutes), thereby preventing ice
crystals from having the time to "ripen" (i.e., grow). Furthermore,
once ice nuclei have formed, conditions that minimize their growth
are needed to keep the ice crystals as small as possible. To obtain
the smallest possible ice crystals, it is necessary to have the
shortest residence time possible in order to minimize "ripening"
(i.e., growth) of the ice crystals. System 10 achieves this by
using multiple internal scraper paddles to remove ice crystals from
the walls of the pod, which helps create high-throughput rates
which keeps the ice crystals small (e.g., under 50 .mu.m).
[0127] When the frozen confection in pod 30 is ready to be
dispensed into the container which has been placed on tray 130 of
machine 20 (i.e., the container from which the frozen confection
will be consumed), or into a cone held above tray 130, vertical
motor 380 moves plunger 330 vertically, causing plunger 330 to
force cap 660 of pod 30 downward, toward base 580 of pod 30, with
outer helical scraper paddle 670 and inner helical scraper paddle
680 longitudinally compressing with the advance of cap 660. This
action reduces the volume of annular recess 620. Vertical motor 380
continues to move plunger 330 vertically, reducing the volume of
annular recess 620, until the force of the frozen confection in pod
30 ruptures weakened portion 810 of pod 30 and the frozen
confection is forced out exit port 830 of pod 30, whereupon the
frozen confection passes through exit port 234 of nest 140 and into
the container set on tray 130 (i.e., the container from which the
frozen confection will be consumed) or into the cone held above
tray 130. This action continues until cap 660 has been forced
against base 580, effectively ejecting all of the frozen confection
out of pod 30 and into the container from which the ice cream will
be consumed.
[0128] Thereafter, the used pod 30 may be removed from machine 20
and, when another single serving of a frozen confection is to be
prepared, it may be replaced by a fresh pod 30 and the foregoing
process repeated.
Alternative Approaches for Cooling the Inner Portion of the Nest
Assembly
[0129] If desired, and looking now at FIG. 22, cylindrical TEC 280
may be replaced by a helical coil 840 which is itself cooled by a
TEC element 850.
[0130] Alternatively, if desired, and looking now at FIG. 23, a TEC
assembly 240 may be mounted to bottom surface 160 of nest 140 so
that TEC assembly 240 can cool hollow cylinder 200 of nest 140 (as
well as the bottom surface of nest 140).
Using the System to Provide a Cold Beverage
[0131] System 10 can also be used to provide a single serving of a
cold beverage. By way of example but not limitation, pod 30 may
contain a supply of ingredients for forming cold tea (also
sometimes referred to as "iced tea"), cold coffee (also sometimes
referred to as "iced coffee"), cold soda, cold beer, etc. In this
circumstance, pod 30 may contain a dry or liquid cold tea mix, a
dry or liquid cold coffee mix, a dry or liquid soda mix or a dry or
liquid beer mix, etc.
[0132] Where system 10 is to be used to provide a single serving of
a cold beverage, a pod 30, containing a supply of the ingredients
used to form the cold beverage, is inserted into nest assembly 50.
Nest assembly 50 is then used to cool pod 30, and cold water is
pumped from cold water tank 440 into pod 30, where it is combined
with the ingredients contained within pod 30, and mixed by outer
helical scraper paddle 670, inner helical scraper paddle 680 and
bottom scraper paddle 690. When mixing is completed, vertical motor
380 is activated to eject the cold beverage into a waiting
container.
[0133] It will be appreciated that where a cold beverage is to be
produced, air may or may not be pumped into pod 30 (e.g., air may
not be pumped into pod 30 when cold tea or cold coffee is being
produced, and air may be pumped into pod 30 when cold soda or cold
beer is being produced).
[0134] It will also be appreciated that where a cold beverage is to
be produced, outer helical scraper paddle 670, inner helical
scraper paddle 680 and bottom scraper paddle 690 may be omitted
from pod 30 if desired.
Using the System to Provide a Hot Beverage
[0135] System 10 can also be used to provide a single serving of a
hot beverage. By way of example but not limitation, pod 30 may
contain a supply of ingredients for forming a hot beverage, e.g.,
hot chocolate, hot coffee, etc. In this situation, pod 30 may
contain a dry mix formed from ingredients which, when mixed with
hot water, provide the desired beverage, e.g., a hot chocolate
powder, an instant coffee mix, etc.
[0136] Where system 10 is to be used to provide a single serving of
a hot beverage, a pod 30, containing a supply of the ingredients
used to form the hot beverage, is inserted into nest assembly 50.
Nest assembly 50 is then used to heat pod 30, and
ambient-temperature water is pumped from ambient-temperature water
tank 430 into pod 30, where it is combined with the ingredients
contained within pod 30, and mixed by outer helical scraper paddle
670, inner helical scraper paddle 680 and bottom scraper paddle
690. Note that TEC assemblies 240 may be used to supply heat to the
outer surfaces of nest 140 by simply reversing the direction of the
electric current flow supplied to TEC elements 250, and cylindrical
TEC 290 may be used to supply heat to the inner column of nest 140,
whereby to heat the contents of pod 30. In addition, if desired,
the ambient-temperature water in ambient-temperature water tank 430
may be heated before injection into pod 30, e.g., via resistance
heaters positioned in the line between ambient-temperature water
tank 430 and hollow fang 410 of plunger 330. It will be appreciated
that where a hot beverage is to be produced, air is generally not
pumped into pod 30.
[0137] In many cases, it may be desirable to "brew" a hot beverage
by passing water through a supply of granulated ingredients, e.g.,
such as in the case of coffee or tea. To that end, and looking now
at FIGS. 24-27, pod 30 can be provided with a filter 860 which
contains a supply of the granulated ingredients (e.g., ground
coffee beans, tea leaves, etc.) which is to be brewed. In one
preferred form of the invention, and as shown in FIGS. 24-27,
filter 860 is disposed adjacent to cap 660, e.g., filter 860 is
secured to cap 660, and outer helical scraper paddle 670, inner
helical scraper paddle 680 and bottom scraper paddle 690 are
omitted from pod 30. Note also that when plunger 330 collapses cap
660 towards base 580, filter 860 will preferably also collapse,
whereby to allow compression of the granulated ingredients
contained within filter 860, so as to press the fluid out of filter
860, e.g., in the manner of a so-called "French Press" coffee
maker. It should also be appreciated that filter 860 is constructed
so that it will maintain its structural integrity during collapse
so that the granulated contents of filter 860 do not pass out of
pod 30.
Cabinet Configuration
[0138] If desired, and looking now at FIG. 28, machine 20 can be
mounted to a cabinet 870, where cabinet 870 sits on legs 880. In
this construction, cabinet 870 can include additional cooling
apparatus for removing heat from heat dissipation assembly 90
(e.g., additional heat pipes, condensers and fans, or a
conventional refrigeration unit, etc.). Cabinet 870 may also be
configured so as to house fresh pods 30 and/or containers for
receiving the frozen confections (e.g., bowls and cones), cold
beverages (e.g., cups) and hot beverages (e.g., cups).
Chilling the Pod with a Refrigeration Coil
[0139] In another form of the invention, and looking now at FIGS.
29-31, nest assembly 50 may be replaced by an alternative nest
assembly 50A comprising a nest 140A in the form of a torus
characterized by an outer wall 220A and an inner wall 230A, wherein
the torus is formed out of a high heat-transfer material (e.g.,
aluminum), and further wherein TEC assemblies 240 are replaced by a
refrigeration coil 240A which is connected to heat dissipation
assembly 90A, wherein heat dissipation assembly 90A comprises a
compressor for driving refrigeration coil 240A.
[0140] It will be appreciated that, as a result of this
construction, nest assembly 50A (and hence a pod 30 disposed in
nest assembly 50A) can be cooled via a conventional refrigeration
system. This construction can be advantageous since it can quickly
cool a pod 30 to -40 degrees C., which is beyond the thermal
performance of TEC elements 250.
Alternative Nest and Pod Constructions
[0141] In the foregoing disclosure, nest assembly 50 and nest
assembly 50A comprise an internal cooling element (e.g., hollow
cylinder 200 containing TEC 280) as well as external cooling
elements (e.g., TEC assemblies 240), and pod 30 comprises an inner
opening (i.e., the lumen of inner hollow tube 610) for receiving
the internal cooling element of nest assemblies 50 and 50A.
However, if desired, the internal cooling element may be omitted
from nest assemblies 50 and 50A, in which case the inner opening of
pod 30 may also be omitted.
Compressor-Cooled Machine with Fixed-Cap Pod
[0142] Looking next at FIGS. 32-35, 35A, 35B and 35C, there is
shown another novel system 900 for providing a single serving of a
frozen confection, e.g., ice cream (soft serve or hard), frozen
yogurt, a frozen protein shake, a smoothie, etc. For the purposes
of the present invention, a single serving of a frozen confection
may be considered to be approximately 2 fluid ounces to
approximately 8 fluid ounces.
[0143] System 900 is also capable of providing a single serving of
a cold beverage, and/or a single serving of a hot beverage.
[0144] System 900 may comprise two nests 915, where one nest 915 is
configured to receive a frozen confection pod at 5-8 ounces and
another adjacent nest 915, which may be smaller in size, is
configured to receive a coffee pod (e.g., a K-Cup pod) or a cold
beverage pod (e.g., an iced tea pod). In this form of the
invention, water (hot or cold) is directed to the proper nest 915
to form the desired cold confection or the desired hot or cold
beverage. See, for example, FIG. 35A, which shows two nests 915 for
producing a desired cold confection or a desired hot or cold
beverage (note that the configuration of system 900 may differ
slightly depending on whether a single nest or double nest is to be
provided). Preferably, a pod detector (not shown) is provided in
each nest 915 to identify which nest has received which type of pod
(e.g., frozen confection, hot coffee, iced tea, etc.) so that the
machine sends the appropriate cold or hot water to the appropriate
nest.
[0145] In a preferred form of the invention, system 900 generally
comprises a machine 905 and a pod 910, wherein machine 905 is
configured to, among other things, receive pod 910 containing a
supply of ingredients for forming a single serving of the frozen
confection, cool pod 910 (and its contents), introduce cold water
and air into pod 910 (where appropriate, see below), agitate the
contents of pod 910 so as to form the frozen confection, and then
eject 3 to 8 ounces of the frozen confection from pod 910 directly
into the container (e.g., a pre-chilled bowl, an ambient bowl, a
cone, etc.) from which it will be consumed.
[0146] In one form of the invention, system 900 is able to form a
frozen confection without introducing water and/or air into pod 910
(see below).
[0147] Machine 905
[0148] Machine 905 is generally similar to machine 20 described
above, except that machine 905 uses a compressor to cool pod 910
and water supply 70 may be omitted in some circumstances (see
below). More particularly, machine 905 comprises a nest 915 for
receiving pod 910, a coolant unit 920 for cooling nest 915, and a
refrigeration unit 925 for cooling coolant unit 920. Machine 905
weighs less than 50 lbs and is configured to produce and dispense
single servings of frozen confections or hot or cold beverages in
quantities of approximately 1 quart or less within 5 minutes or
less. The frozen confection will have between 10-60% overrun (i.e.,
air content) per single serving batch. It should be appreciated
that the amount of overrun varies according to the particular
product being made in pod 910.
[0149] More particularly, nest 915 comprises a body 930 defining a
tapered (preferably frustoconical) recess 935 for receiving a
correspondingly tapered (preferably frustoconical) pod 910 and an
interior chamber 940 for cooling recess 935 of nest 915. Nest 915
further comprises an inlet 945 leading to interior chamber 940 and
an outlet 950 leading from interior chamber 940.
[0150] In one form of the invention, tapered recess 935 of nest 915
comprises a smaller first end 951, a larger second end 952 and a
tapered side wall 953 extending between the smaller first end 951
and the larger second end 952. In one preferred form of the
invention, tapered recess 935 is frustoconical. In one form of the
invention, tapered side wall 953 of recess 935 has a taper of
approximately 5 degrees or greater. In one form of the invention,
smaller first end 951 may be closed off. In another form of the
invention, smaller first end 951 may be partially open. In another
form of the invention, smaller first end 951 may be completely
open. See, for example, FIG. 35B and FIG. 35C, which show
additional configurations for nest 915 (and which also show
additional configurations for pod 910).
[0151] It should be appreciated that where smaller first end 951 of
nest 915 is either partially open or completely open, it may be
possible to create a better fit of pod 910 in nest 915. More
particularly, with the bottom of nest 915 partially or fully open,
pod 910 fits in nest 915 without "bottoming out" so a better fit is
created between the walls of the nest and the walls of the pod,
thereby allowing for much more efficient cooling of the pod.
[0152] Coolant unit 920 comprises a reservoir 955 for containing a
supply of coolant, a circulation motor 960, a line 965 connecting
reservoir 955 to circulation motor 960, a line 970 connecting
circulation motor 960 with inlet 945 of nest 915, and a line 975
connecting outlet 950 of nest 915 with reservoir 955. As a result
of this construction, coolant contained in reservoir 955 can be
circulated through interior chamber 940 of nest 915 so as to cool a
pod 910 contained in recess 935 of nest 915.
[0153] Refrigeration unit 925 comprises a refrigeration cycle
comprising a compressor 980, a condenser 985, an expansion valve
(not shown) located downstream of the condenser, and an evaporator
(not shown, but could be an immersion coil in a coolant tank)
located at reservoir 955 of coolant unit 920, such that compressor
980 can drive a refrigerant through the refrigeration cycle to cool
the coolant disposed within reservoir 955 of coolant unit 920.
[0154] As a result of this construction, refrigeration unit 925 can
be used to cool coolant unit 920, and coolant unit 920 can be used
to cool a pod 910 disposed in nest 915. Note that by selecting an
appropriate coolant for coolant unit 920, and by providing a
reservoir 955 of appropriate size, sufficient "cold" can be
accumulated within coolant unit 920 so that multiple batches of
frozen confection can be sequentially produced with substantially
no lag time.
[0155] Eutectic Solution
[0156] In one preferred form of the invention, at least one
container holding a eutectic solution is disposed adjacent to the
pod seat of nest 915. This eutectic solution is used to store
"cold" at the nest. More particularly, coolant unit 920 is used to
cool the eutectic solution to the point of freezing, and then the
eutectic solution absorbs heat from pod 910, whereby to produce the
frozen confection.
[0157] More particularly, while system 900 is parked idle (i.e.,
prior to producing servings of a frozen confection), compressor 980
of refrigeration unit 925 is turned on. Compressor 980 circulates
its refrigerant (e.g., Freon, Norflurane referred to as R-134A,
R-407C, R-404A, R-410A, etc.) through its refrigeration cycle so as
to cool the coolant in reservoir 955 of coolant unit 920, and then
the coolant in reservoir 955 cools the eutectic solution contained
within at least one container in nest 915 to 0.degree. C. to
-114.degree. C. Once the eutectic solution surrounding nest 915 is
cooled to 0.degree. C. to -114.degree. C., system 900 automatically
turns off compressor 980 of refrigeration unit 925. Note that
compressor 980 of refrigeration unit 925 does not need to run while
system 900 is making the frozen confection, since the
already-cooled coolant in coolant unit 920, and/or the eutectic
solution in at least one container in the nest, is actually used to
cool a pod 910 in nest 915. Of course, compressor 980 of
refrigeration unit 925 may be run while system 900 is making the
frozen confection if desired.
[0158] It will be appreciated that the cold lost from the eutectic
solution by removing heat from pod 910 is replaced by a heat
exchange as the cooled eutectic solution slowly warms. This
maintains the temperature of nest 915 between -40.degree. C. and
0.degree. C. while making multiple pods of a frozen confection in
quick succession. As the eutectic solution warms, circulation motor
960 of coolant unit 920 keeps pumping coolant to the nest to help
carry the cooling load of the eutectic container. Additionally,
compressor 980 of refrigeration unit 925 automatically turns back
on, pumping refrigerant to coolant unit 920 (which is re-cooling
the eutectic solution).
[0159] Between cooling of a pod and/or between uses of machine 905,
frost may accumulate on the inside of nest 915. Flashing heat to
the surface of nest 915 defrosts the surface of nest 915. This
flash heat may be in the form of warm air, induction coil heat,
resistance heat, etc.
[0160] It should be appreciated that the eutectic solution
comprises a phase change material. In this respect, it should also
be appreciated that phase change materials (PCMs) are compositions
that store and release thermal energy during the processes of
warming and cooling. Phase change materials typically release (in
the form of latent heat) large amounts of energy upon cooling, but
absorb equal amounts of energy from the immediate environment upon
warming. In this way, phase change materials enable thermal energy
storage: heat or cold being stored at one period of time and used
at a later point in time.
[0161] It should be appreciated that a simple, cheap and effective
phase change material is water/ice. Unfortunately, water/ice has a
freezing point of 0.degree. C. (+32.degree. F.), which precludes
water/ice from the majority of energy storage applications.
However, a number of alternative phase change materials have been
identified and developed that cool and warm like water/ice, but at
temperatures from the cryogenic range to several hundred degrees
centigrade. When salts are added to water, they depress the
freezing point of the water. Adding more salt generally depresses
the freezing temperature further, but these solutions do not freeze
cleanly and at a precise temperature, instead they tend to form a
slush. However, if a particular salt at a particular concentration
is added to water, the resulting solution freezes and melts cleanly
at a constant temperature, releasing and storing large amounts of
energy as it does so. This temperature is called the eutectic point
and the composition is called a eutectic solution. This is
represented in the simplified graph shown in FIG. 36. The curved
line on the graph of FIG. 36 represents the freezing curve.
Starting from the left of the curve, the composition is 100% water
and the freezing point is 0.degree. C. (32.degree. F.). As salt is
added, the freezing point of the salt/water mixture decreases. When
freezing occurs in this section of the graph, only pure water
freezes out of solution and the salt remains in solution. If more
salt is added, the freezing point depresses further until the
eutectic point is reached at the lowest freezing point on the
curve. Some PCMs are a gel. PCMs can be made of sodium
polyacrylate, salt hydrates, or paraffins which are high molecular
mass hydrocarbons with a waxy consistency at room temperature.
Paraffins are made up of straight chain hydrocarbons and vegetable
based PCMs. Below is a list of sub-zero eutectic PCM solutions with
phase changes ranging from 0 to -114.degree. C.
TABLE-US-00001 Phase Change Latent Heat PCM Temperature Density
Capacity Type (.degree. C.) (.degree. F.) (kg/m3) (lb/ft3) (kJ/kg)
Btu/lb) E0 0 32 1,000 62.4 332 143 E-2 -2.0 28 1,070 66.8 306 132
E-3 -3.7 25 1,060 66.2 312 134 E-6 -6.0 21 1,110 69.3 275 118 E-10
-10.0 14 1,140 71.2 286 123 E-11 -11.6 11 1,090 68.0 301 129 E-12
-12.3 10 1,110 69.3 250 108 E-14 -14.8 5 1,220 76.2 243 105 E-15
-15.0 5 1,060 66.2 303 130 E-19 -18.7 -2 1,125 70.2 282 121 E-21
-20.6 -5 1,240 77.4 263 113 E-22 -22.0 -8 1,180 73.7 234 101 E-26
-26.0 -15 1,250 78.0 280 112 E-29 -29.0 -20 1,420 88.6 222 95 E-32
-32.0 -26 1,290 80.5 243 105 E-34 -33.6 -28 1,205 75.2 240 103 E-37
-36.5 -34 1,500 93.6 213 92 E-50 -49.8 -58 1,325 82.7 218 94 E-75
-75.0 -103 902 56.3 102 44 E-78 -78.0 -108 880 54.9 115 49 E-90
-90.0 -130 786 49.1 90 39 E-114 -114.0 -173 782 48.8 107 46
TABLE-US-00002 Volumetric Heat Specific Heat Thermal Capacity
Capacity Conductivity PCM (Btu/ (kJ/ (Btu/ (Btu/ft2 Type (MJ/m3)
ft3) kgK) lb .degree. F.) (W/mK) h .degree. F.) E0 332 8,911 4.186
0.992 0.580 0.335 E-2 327 8,777 3.80 0.900 0.580 0.335 E-3 331
8,884 3.84 0.910 0.600 0.347 E-6 305 8,186 3.83 0.907 0.560 0.324
E-10 326 8,750 3.33 0.789 0.560 0.324 E-11 328 8,804 3.55 0.841
0.570 0.329 E-12 278 7,462 3.47 0.822 0.560 0.324 E-14 296 7,945
3.51 0.832 0.530 0.306 E-15 321 8,616 3.87 0.917 0.530 0.306 E-19
344 9,233 3.29 0.779 0.580 0.335 E-21 326 8,750 3.13 0.741 0.510
0.295 E-22 276 7,408 3.34 0.791 0.570 0.329 E-26 325 8,723 3.67
0.869 0.580 0.335 E-29 264 7,086 3.69 0.874 0.640 0.370 E-32 313
8,401 2.95 0.699 0.560 0.324 E-34 286 7,676 3.05 0.723 0.540 0.312
E-37 302 8,106 3.15 0.746 0.540 0.312 E-50 283 7,596 3.28 0.777
0.560 0.324 E-75 92 2,469 2.43 0.576 0.170 0.098 E-78 101 2,716
1.96 0.464 0.140 0.081 E-90 71 1,906 2.56 0.606 0.140 0.081 E-114
84 2,255 2.39 0.566 0.170 0.098
[0162] Compressor 980
[0163] If desired, a conventional reciprocating compressor (e.g.,
the Tecumseh TC1413U-DS7C compressor) may be used for compressor
980 of refrigeration unit 925. Alternatively, rotary compressors
(e.g., such as those made by Aspen Systems, Samsung and Rigid) may
be used for compressor 980 of refrigeration unit 925.
Alternatively, a
Direct Current Compressor R290-12-24 V by Danfoss with evaporating
temperatures ranging from -40.degree. C. to 10.degree. C. may be
used.
[0164] Tubing for the Refrigeration Cycle
[0165] As noted above, refrigeration unit 925 circulates
refrigerant from compressor 980, through condenser 985, through an
expansion valve (not shown) located downstream of the condenser,
and through an evaporator (not shown) located at reservoir 955 of
coolant unit 920. In one form of the invention, conventional
refrigeration tubing is used to transfer the refrigerant between
the various components of refrigeration unit 925. In another form
of the invention, and looking now at FIG. 37, a coaxial
refrigeration tube may be used to transfer the refrigerant between
the various components of refrigeration unit 925, whereby to gain
enhanced refrigeration efficiency.
[0166] One Preferred Arrangement for Cooling a Pod Disposed in the
Nest
[0167] In one preferred form of the invention, where nest 915 is
cooled using a eutectic solution contained in one or more
containers at nest 915, both coolant unit 920 and the eutectic
solution container(s) are able to store "cold" so as to increase
the efficiency of system 900. More particularly, compressor 980
drives refrigerant through reservoir 955 of coolant unit 920 so as
to cool the coolant in reservoir 955, whereby to store "cold" in
reservoir 955. The coolant in reservoir 955 is then driven to the
eutectic solution container(s) in nest 915 by circulation motor 960
of coolant unit 920 so as to cool the eutectic solution, whereby to
store additional "cold" in the nest. See FIG. 37A. In this way,
multiple batches of frozen confection may be made in succession
inasmuch as there is sufficient "cold" stored in the system to
allow for cooling of multiple pods without having to wait for
refrigeration unit 925 to cool multiple batches of frozen
confection. Additionally, compressor 980 does not need to be
constantly running in order for multiple batches of frozen
confection to be made.
[0168] Direct Expansion Refrigeration of Nest 915
[0169] In a preferred form of the invention, refrigeration unit 925
is used to cool the coolant in reservoir 955 of coolant unit 920,
and coolant unit 920 is used to cool nest 915 (or the eutectic
solution contained in one or more containers at nest 915), whereby
to cool a pod 910 disposed in nest 915. However, if desired, a
direct expansion system may be used to cool nest 915. A direct
expansion system eliminates the use of a secondary coolant loop
(i.e., the coolant loop of coolant unit 920) and uses the
refrigerant of refrigeration unit 925 to directly cool nest 915 via
a cold plate. The cold plate can be customized to generate a very
high heat flux, operating at temperatures well below ambient. In
the cold plate of a direct expansion system, the refrigerant from
refrigeration unit 925 undergoes an isothermal phase change,
offering tight temperature control across the cold plate. As seen
in FIG. 38, a direct expansion system consists of the basic 4
components of a vapor compression refrigeration system: a
compressor, a condenser, an expansion valve, and an evaporator. In
a direct expansion system, the evaporator absorbs heat directly
from nest 915. Inasmuch as no secondary coolant loop is required
(i.e., coolant unit 920 is eliminated), minimal parts are needed in
the direct expansion system. No fans are required to circulate cool
air and no pump is required to circulate the coolant, which
simplifies system construction and improves system efficiency.
[0170] Another Preferred Arrangement for Cooling a Pod Disposed in
the Nest
[0171] In another preferred form of the invention, at least one
container holding a eutectic solution is disposed adjacent to the
pod seat of nest 915. Refrigeration unit 925 is used to directly
cool the eutectic solution to the point of freezing. In this form
of the invention, coolant unit 920 is eliminated. Compressor 980
drives refrigerant directly through nest 915 so as to cool the
eutectic solution in the container(s) adjacent to the pod seat in
nest 915, whereby to store "cold" in the nest. See FIG. 38A. In
this way, multiple batches of frozen confection may be made in
succession as there is sufficient "cold" stored in the nest to
allow for cooling of multiple pods without having to wait for
refrigeration unit 925 to cool multiple batches of frozen
confection. Additionally, compressor 980 does not need to be
constantly running in order for multiple batches of frozen
confection to be made.
[0172] Pod 910
[0173] Pod 910 is generally similar to pod 30 described above,
except that pod 910 has its cap permanently fixed in place and is
sealed shut. In the preferred form of the invention, pod 910 is
provided as a single use, disposable pod, i.e., a new pod is used
for each serving of the frozen confection (or hot or cold
beverage). However, it should be appreciated that, if desired, pod
910 may be provided as a multi-use, reusable pod, i.e., a pod may
be reused (after filling with fresh ingredients) to provide
additional servings of the frozen confection (or hot or cold
beverage). Where pod 910 is reusable, the cap of the pod is
selectively removable from the remainder of the pod.
[0174] Pod 910 is provided with an inner scraper paddle made of
plastic which is configured to eject the frozen confection out the
bottom of the pod by reversing the direction of the inner scraper
paddle. The inner scraper paddle can be made by injection molding
or 3D printing.
[0175] More particularly, and looking now at FIGS. 35, 35B, 39-42,
42A and 42B, pod 910 generally comprises a canister 990, an
internal scraper paddle assembly 995 and a cap 1000.
[0176] Canister 990 is tapered (preferably frustoconical) and
comprises a floor 1005 and a side wall 1010 upstanding therefrom.
In one form of the invention, tapered canister 990 comprises a
smaller floor 1005, a larger cap 1000 and a tapered side wall 1010
extending between the smaller floor 1005 and the larger cap 1000.
In one preferred form of the invention, tapered canister 990 is
frustoconical. Note that the taper of canister 990 matches the
taper of nest 915, so that pod 910 can make a close fit within nest
915, whereby to facilitate excellent heat transfer between the pod
and the nest.
[0177] In another form of the invention, tapered side wall 1010 has
a taper of approximately 5 degrees or greater.
[0178] Canister 990 has an opening 1015 in its base. A nozzle 1020
is formed adjacent to opening 1015. A sliding gate 1025 selectively
opens or closes opening 1015 as will hereinafter be discussed. A
stop 1030 is formed on floor 1005 to limit movement of sliding gate
1025.
[0179] In one form of the invention, tapered side wall 1010 has a
uniform thickness along its length.
[0180] In another form of the invention, tapered side wall 1010 has
a thickness which varies along its length. More particularly,
tapered side wall 1010 may be thinner adjacent to the smaller floor
1005 and may be thicker adjacent to the larger cap 1000, such that
the pod ingredients will freeze faster adjacent to smaller floor
1005 than the pod ingredients will freeze adjacent to larger cap
1000.
[0181] It should be appreciated that providing canister 990 with a
tapered side wall 1010 is important for creating good surface
contact between pod 910 and nest 915 (i.e., between tapered side
wall 1010 of pod 910 and tapered side wall 953 of nest 915).
Providing a close fit between pod 910 and nest 915 is critical for
adequate heat transfer from nest 915 to pod 910 in order to
efficiently freeze the contents of pod 910. It should also be
appreciated that providing canister 990 with a tapered side wall
1010 focuses the contents of the pod so that the contents move
toward opening 1015 in canister 990 of pod 910. Specifically, when
pod 910 is used to make a frozen confection, tapered side wall 1010
focuses the frozen confection as it freezes toward opening 1015 and
out nozzle 1020.
[0182] Canister 990 preferably comprises a thin side wall formed
out of a material which has high heat transfer capability, e.g., a
thin metal, a thin plastic, etc. Canister 990 is preferably 50-500
microns thick so as to provide a high heat transfer rate between
nest 915 and pod 910. Canister 990 is also preferably somewhat
deformable so that canister 990 has some ability to expand against
nest 915, whereby to ensure high heat transfer between the pod and
the nest.
[0183] Internal scraper paddle assembly 995 comprises a plurality
of scraper blades 1035 which have a generally helical
configuration. In one form of the invention, the scrapper blades
1035 can have a rubber squeegee on the ends of the blades so as to
better conform to and scrape the inner wall of pod 910. Preferably
openings 1040 are formed in scraper blades 1035. Internal scraper
blade assembly 995 also comprises an upwardly-projecting stem 1045
which can rotate at speeds from 10 to 400 RPM.
[0184] Cap 1000 is secured to (i.e., permanently fixed to) canister
990. Cap 1000 comprises an opening 1050 for admitting fluids (e.g.,
liquid or air) into the interior of canister 990 and an opening
1055 for permitting upwardly-projecting stem 1045 to project out of
the interior of canister 990.
[0185] Cap 1000 and floor 1005 can be made of insulating materials
or coated with insulating materials, e.g., aerogels.
[0186] Prior to use, opening 1015 in floor 1005, and opening 1050
in cap 1000, are closed off with rupturable membranes.
[0187] As a result of the foregoing construction, when
upwardly-projecting stem 1045 is turned in a first
(counterclockwise) direction, sliding gate 1025 is urged into its
closed configuration and the contents of pod 910 are forced upward
toward cap 1000. When upwardly-projecting stem 1045 is turned in
the opposite (clockwise) direction and rotated at speeds ranging
from 10 to 400 RPM, sliding gate 1025 is urged into its open
configuration and the contents of pod 910 are forced downward,
against floor 1005 of canister 990, whereupon the rupturable
membrane covering opening 1015 in floor 1005 fails, allowing the
contents of pod 910 to exit through opening 1015 and thus nozzle
1020.
[0188] In another form of the invention, nozzle 1020, sliding gate
1025 and stop 1030 may be omitted, and opening 1015 may be closed
off with a removable seal 1060 (see FIG. 42A). In this form of the
invention, as internal scraper paddle assembly 995 is turned in one
direction, the contents of the pod are forced downward (via
plurality of scraper blades 1035) until the churning contents hit
floor 1005, and then the contents move upward within the pod (see
FIG. 42B), with openings 1040 of plurality of scraper blades 1035
facilitating the upward rise of the contents of the pod. Note that
the contents of the pod are also forced in a radially-outward
direction during mixing, which helps apply a radially-outward force
to tapered side wall 953 of nest 915, which helps seating of the
tapered side wall 1010 of pod 910 against the tapered side wall 953
of nest 915, which enhances heat transfer between the pod and the
nest. When the contents of the pod are to be released, removable
seal 1060 is removed, and the contents of the pod exit through
opening 1015. Note that in this form of the invention, the
direction of turning scraper blades 1035 does not need to be
reversed when discharging the frozen confection from the pod.
[0189] In one preferred form of the invention, pod 910 may comprise
multiple compartments or zones that house different contents, i.e.,
powder ice cream in one zone and a cream or milk or water in a
second zone. When the lid of machine 905 closes, the separating
membrane between zones can puncture or rupture allowing the various
contents to mix.
[0190] Close Fit Between Pod 910 and Nest 915
[0191] In practice, it has been found that providing a close fit
between pod 910 and nest 915 facilitates rapid heat transfer
between pod 910 and nest 915, and hence enables faster production
of a single serving of a frozen confection. Such a close fit may be
provided in a variety of ways.
[0192] By way of example but not limitation, pod 910 could include
screw threads (not shown) on the outside surface of canister 990
and nest 915 could include counterpart screw threads (not shown) on
the surfaces of recess 935 of nest 915, such that pod 910 can be
screwed into close contact with nest 915.
[0193] By way of further example but not limitation, frustoconical
canister 990 of pod 910 could have an incline, and frustoconical
recess 935 of nest 915 could have a corresponding incline, such
that when the lid assembly of machine 905 is closed, pod 910 is
driven downward into a close fit with nest 915.
[0194] By way of still further example but not limitation, pod 910
may be configured so that when a force is applied to the upper end
of pod 910, pod 910 expands slightly so as to bring itself into
closer proximity with recess 935 of nest 915.
[0195] Or a pressurized fluid (e.g., air, CO.sub.2 or Nitrogen) may
be injected into the interior of pod 910 so as to swell the side
wall of canister 990 of pod 910 into closer proximity to recess 935
of nest 915.
[0196] By way of further example but not limitation, recess 935 of
nest 915 could comprise a flexible bladder 1065 (FIG. 43) for
receiving canister 990 of pod 910, such that the flexible bladder
makes a close fit with a pod 910 disposed in nest 915.
[0197] By way of further example but not limitation, recess 935 of
nest 915 could comprise a magnetic material for receiving a ferrous
alloy (i.e., steel) canister 990 of pod 910, such that pod 910 is
magnetically pulled into nest 915 so as to make a close fit with a
pod 910 disposed in nest 915.
[0198] Contents of Pod 910
[0199] The contents of pod 910 may be the same as the contents of
pod 30 discussed above.
[0200] It should also be appreciated that, if desired, pod 910 may
have a conventional yogurt product (e.g., yogurt in a gel-like
form) sealed therein, such that novel system 900 thereafter forms
frozen yogurt for dispensing into a container (e.g., a bowl, a
cone, etc.).
[0201] Furthermore, if desired, pod 910 may contain liquid
ingredients which, when cooled and agitated, form the desired
frozen confection. In this form of the invention it may not be
necessary to pump any further ingredients into the pod in order to
create the desired frozen confection.
[0202] In addition to the foregoing, if desired, and looking now at
FIG. 44, "bubble beads" (e.g., an encapsulant surrounding CO.sub.2
or N.sub.2) may be contained in the ingredients disposed within pod
910. This encapsulant is selected so that when water is added to
the interior of pod 910, the encapsulant dissolves, releasing the
CO.sub.2 or N.sub.2 and creating a "fizz" in the frozen
confection.
[0203] It is also anticipated that pod 910 may comprise the
contents necessary to make a frozen protein shake, e.g., a whey
protein powder, a casein protein powder, a pea protein powder, a
soy protein powder, etc., essentially any powder which, when mixed
with water and chilled, will make a frozen protein shake.
[0204] In one preferred form of the invention, where a frozen
protein shake is to be produced, the contents of pod 910 may
be:
[0205] 3-10% milk fat such as cream, plastic cream, butter,
anhydrous milk fat/butter oil, nondairy fat such as palm oil, palm
kernel oil, coconut oil and other safe and suitable vegetable
oils;
[0206] 9-15% milk solids non-fat (MSNF) such as concentrated
(condensed/evaporated) milk, sweetened condensed milk, milk powder,
skim or whole sweet cream buttermilk, concentrated or dried whey,
concentrated or dried, milk protein concentrates whey protein
concentrates or isolates hydrolyzed or modified milk proteins,
sodium caseinate;
[0207] 4-14% sugar and corn syrup sweetener ingredients; up to 0.5%
stabilizers or thickeners such as sodium carboxymethyl cellulose
(cellulose gun), guar gum, locust bean gum, sodium alginate,
propylene glycol alginate, xanthan, carrageenan, modified starches,
microcrystalline cellulose (cellulose gel), gelatin, calcium
sulfate, propylene glycol monostearate or other monoesters, and
others;
[0208] up to 0.5% emulsifiers such as mono- and diglycerides,
distilled monoglycerides (saturated or unsaturated),
polyoxyethylene sorbitan monostearate (60) or monooleate (80), and
others; and
[0209] have 5 to 60 grams of protein in the form of whey, casein,
pea, soy and or a combination of said proteins.
[0210] In each 3-8 ounce serving of frozen protein shake, there
ideally would be greater than 10 grams of protein and less than 200
calories.
[0211] Further examples of the pod ingredients can include the
following soft serve ice cream powder, powder yogurt, powder shake
mix, liquid slush mix, powder coffee base mix, powder smoothie mix,
powder or liquid low sweet neutral base and premium neutral base
ingredients are listed below:
TABLE-US-00003 SOFT SERVE Item# Type Manufacturer Dole Vanilla Soft
D500 Powder Precision Foods Serve Dole Chocolate soft D510 Powder
Precision Foods Serve Frostline Vanilla D400 Powder Precision Foods
Soft Serve Frostline Chocolate D410 Powder Precision Foods Soft
Serve Frostline Vanilla DL28 Liquid Precision Foods Soft Serve
(RTU) Frostline Chocolate DL27 Liquid Precision Foods Soft Serve
(RTU) FROZEN YOGURT Item# Type Manufacturer Frostline Vanilla Y800
Powder Precision Foods Yogurt Frostline Chocolate Y810 Powder
Precision Foods Yogurt SHAKES Item# Type Manufacturer Frostline
Vanilla D425 Powder Precision Foods Shake Mix SLUSH Item# Type
Manufacturer Flavor Burst Premium FLA NB-3 Liquid Flavor Burst
Neutral Base Company 6 half-gallon jugs per case - 1:5 mixing
ration FROZEN COFFEES Item# Type Manufacturer JavaLatte Coffee Base
FLA-JL-2 Powder Flavor Burst requires soft service Company mix -
see available soft serve mixes above SMOOTHIES Item# Type
Mnaufacturer Frostline Smoothie D595 Powder Precision Foods Base
Mix FROZEN CARBONATED BEVERAGE (FCB) Item# Type Manufacturer
National Fruits Liquid National Fruit Flavors Flavor Chilly Willee
Liquid Chilly Willee National, Inc FRUIT COCKTAILS - See receipt
below! Item# Type Manufacturer Low Sweet Neutral Powder United
Citrus Base Flavor Burst Premium FLA-NB-3 Liquid Flavor Burst
Neutral Base Company
Soft Serve Ice Cream Mix Construction
[0212] In another form of the invention, when forming a single
serving of soft serve ice cream, water supply 70 may be replaced by
a cooler (not shown). The cooler may accept a container (e.g., a
plastic bottle or a plastic bag) which holds approximately 1.0
liter to approximately 3.0 liters of liquid soft serve ice cream
mix. In this form of the invention, pod 910 is used to form the
single serving of soft serve ice cream, by receiving the liquid
soft serve ice cream mix and agitating the single serving of soft
serve ice cream mix while it is cooling.
[0213] It should be appreciated that by injecting a liquid soft
serve ice cream mix into pod 910, fluid (i.e., air or liquid) does
not need to be subsequently injected into the pod in order to
create the frozen confection (i.e., the soft serve ice cream). When
pod 910 has been appropriately cooled, rotation of internal paddle
assembly 995 forms a single serving of soft serve ice cream in pod
910.
[0214] Additionally, in this form of the invention, a separate
water reservoir tank (not shown) may be provided which is able to
pump approximately 0.5 ounce to approximately 1.0 ounce of water
through the tube connecting the container (e.g., the plastic bottle
or the plastic bag) to the pod so as to flush residual liquid soft
serve ice cream mix from the tube before the next single serving of
soft serve ice cream is prepared using novel system 900.
MODIFICATIONS OF THE PREFERRED EMBODIMENTS
[0215] It should be understood that many additional changes in the
details, materials, steps and arrangements of parts, which have
been herein described and illustrated in order to explain the
nature of the present invention, may be made by those skilled in
the art while still remaining within the principles and scope of
the invention.
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