Methods and Apparatus for Automated Food Preparation
Methods and apparatus for automatically preparing food for consumption in which preparation comprises dispensing, manipulation, heating, and other operations using a wide variety of ingredients. The methods and apparatus described use ingredients efficiently and maintain their quality, while avoiding contact between ingredients and apparatus to minimize the risk of system contamination.
The table below sets forth the priority claims for the instant application along with filing dates, and patent numbers as appropriate. Each of the listed applications is incorporated herein by reference as if set forth in full herein including any appendices attached thereto.
This disclosure generally relates to the fields of robotics/automation and cooking/culinary arts.
SUMMARYThe automation of food preparation is of significant interest. A highly-automated food preparation system/machine/kiosk/appliance can offer significant benefits, providing a means of reducing labor that is frequently hard to find and costly and allowing installation in locations unsuitable for workers; increasing the availability of quality food and allowing access in more locations and at more times; reducing wait times; facilitating customization to individual tastes, nutritional requirements, and dietary restrictions; reducing the risk of foodborne illness caused by restaurant workers; increasing repeatability by making recipes more quantitative and ensuring they are followed accurately; etc.
Key issues associated with automated food preparation may be addressed by packaging, providing, and storing ingredients within sealed flexible packages (pouches)—with each pouch containing the amount of an ingredient required for a particular recipe, given the number of servings to be prepared—rather than in bulk form (e.g., contained within a large bin or hopper).
It is an object of some embodiments of the invention to assure high ingredient quality by protecting ingredients before use from exposure to the environment, since air and moisture can cause oxidation, desiccation, sogginess, staleness, and other degradation which reduce palatability, and require frequent and wasteful restocking with fresh ingredients.
It is an object of some embodiments of the invention to assure food safety and hygiene by minimizing or eliminating durable components of the apparatus coming into direct contact with ingredients, since otherwise there is danger (without perfect cleaning, which is difficult to achieve) of harmful microbes growing (within residues of food remaining on surfaces) which can then enter uncontaminated food, or of cross-contamination from other ingredients (including allergens such as peanuts), and if ingredients are not well protected, insects and other vermin may infest them.
It is an object of some embodiments of the invention to offer meal variety by providing dispensing methods and apparatus that are compatible with a very large range of ingredients, including those that might be too delicate, too large, too moist, etc. to dispense by other methods.
It is an object of some embodiments of the invention to provide efficient and non-wasteful dispensing of ingredients by such that virtually the entire amount of ingredient provided for a particular meal is delivered and there is little or nothing left behind
It is an object of some embodiments of the invention to minimize maintenance of systems which automate food preparation, and reduce the need for human intervention.
Other objects and advantages of various embodiments of the invention will be apparent to those of skill in the art upon review of the teachings herein. The various embodiments of the invention, set forth explicitly herein or otherwise ascertained from the teachings herein, may address one or more of the above objects alone or in combination, or alternatively may address some other object ascertained from the teachings herein. It is not necessarily intended that all objects be addressed by any single aspect of the invention even though that may be the case with regard to some aspects.
In a first aspect of the invention a method for manipulating a flexible package comprising flaps, includes: (a) providing a flexible package wherein the package comprises at least one flexible film comprising a left portion and a right portion with each portion having an inside and an outside surface with the inside surfaces facing each other and wherein the left and right portions have regions that are sealed one to the other and wherein each portion comprises a distal flap; (b) contacting the flap of the left portion using first contacting means; (c) contacting the flap of the right portion using second contacting means; (d) moving the two contacting means and separating the two flaps from one another.
Numerous variations of the first aspect of the invention are possible and include, for example: 1) the moving comprising pushing or pulling on the flaps; 2) the contacting means selected from the group consisting of i) suction cups, ii) adhesive pads, iii) clamps, iv) pins, v) microstructured adhesive, and vi) electrostatically-attracted pads; 3) moving each flap to a position and orientation where it can be grasped by clamping means.
In a second aspect of the invention a method for manipulating a flexible package comprising flaps, includes: (a) providing a flexible package wherein the package comprises at least one flexible film comprising a left portion and a right portion and wherein the left and right portions have regions that are sealed one to the other and wherein each portion comprises a distal flap; (b) introducing deflecting means between the flaps; (c) moving the deflecting means relative to the flaps; whereby the flaps are separated from one another.
Numerous variations of the second aspect of the invention are possible and include, for example: 1) wherein the flexible package comprises a loop of flexible film configured to allow access to the deflecting means; 2) further comprising moving each flap to a position and orientation where it can be grasped by clamping means.
In a third aspect of the invention a method for dispensing at least one substance from a sealed flexible package, includes: (a) providing a sealed flexible package containing at least one substance wherein the package comprises at least one flexible film comprising a left portion and a right portion with each portion having an inside and an outside surface with the inside surfaces facing each other and wherein the portions are partially sealed to one another to form at least one compartment containing the at least one substance and wherein the seal comprises at least one openable region and wherein each portion comprises an unsealed flap; (b) grasping the flap of the left portion using left grasping means; (c) grasping the flap of the right portion using right grasping means; and (d) moving the left and right grasping means to apply tension to the flaps; whereby the openable region of the seal is opened and at least a portion of the at least one substance is dispensed from the at least one compartment.
Numerous variations of the third aspect of the invention are possible and include, for example wherein the first and second grasping means comprise at least one clamp.
In a fourth aspect of the invention a flexible package containing at least one item wherein the package includes: (a) at least one flexible film comprising a left portion and a right portion with each portion having an inside and an outside surface with the inside surfaces facing each other; and (b) wherein the portions are partially sealed to one another to form at least one compartment containing the at least one item; and (c) wherein the seal comprises at least one openable seal region; and (d) wherein each portion comprises an unsealed extension at one end; and (e) wherein each extension is narrower than a sealed region of the portion from which it extends; and (f) wherein the two extensions do not completely overlap.
In a fifth aspect of the invention an apparatus for use with a sealed flexible package having a substance contained in a cavity and comprising at least one flap, the apparatus includes (a) means for holding and positioning a sealed flexible package; (b) grasping means to grasp at least one flap of the package; (c) movement means to move the grasping means relative to the package cavity.
Numerous variations of the fifth aspect of the invention are possible and include, for example wherein the substance is flowable and further comprising expelling means to expel the substance from the package selected from the group consisting of i) at least one squeegee, ii) at least one roller, and iii) at least one inflatable bladder.
In a sixth aspect of the invention an apparatus for use with a flexible package containing at least one flowable substance, includes: a) means for holding and positioning a flexible package; b) retractable impingement means configured to impinge on the package to discharge the at least one flowable substance from the package.
Numerous variations of the sixth aspect of the invention are possible and include, for example: 1) wherein the impingement means retracts by rotating; 2) wherein the impingement means is selected from the group consisting of i) squeegee, ii) roller, and iii) inflatable bladder.
In a seventh aspect of the invention a method for dispensing at least one substance from a sealed flexible package, includes: (a) providing a sealed flexible package containing at least one substance wherein the package comprises at least one flexible film comprising a left portion and a right portion with each portion having an inside and an outside surface with the inside surfaces facing each other and wherein the portions are partially sealed to one another to form at least one cavity containing the at least one substance and wherein the seal comprises at least one openable seal and wherein each portion comprises an unsealed extension at one end and wherein each extension is narrower than a sealed region of the portion from which it extends; (b) grasping the extension of the left portion using first grasping means; (c) grasping the extension of the right portion using second grasping means; (d) moving the first and second grasping means to pull the two extensions away from one another; whereby the seal is opened and at least a portion of the at least one substance is dispensed from the cavity.
Numerous variations of the seventh aspect of the invention are possible and include, for example: 1) wherein the first and second grasping means move along a path that is at least partially curved; 2) wherein the first and second grasping means each comprise a clamp having leading and trailing portions; 3) wherein the first and second grasping means move substantially below the flexible package when grasping the extensions.
In an eighth aspect of the invention a storage device for flexible packages having at least one edge, includes: (a) at least one upper surface oriented at a non-zero angle to the horizontal and configured to support a flexible package resting thereupon and comprising a lower end; (b) at least one stop proximate the lower end of the surface configured to contact an edge of the package and prevent motion of the package past the lower end whenever the pouch is not actively withdrawn from the device.
Numerous variations of the eighth aspect of the invention are possible and include, for example: 1) wherein the surface comprises a cutout at its lower end to allow access to an edge of the package by a mechanism for withdrawing the package; 2) variation (1) wherein the mechanism further comprises at least one gripper; 2) further comprising an actuator that generates vibration to cause the package to move along the surface toward its lower end; 3) further comprising at least one ramp to guide a leading edge of the package to a known position within the device and wherein the at least one ramp does not prevent removal of the package from the device; 4) variation (2) wherein the storage device further comprises a pair of upper and a pair of lower ramps positioned to guide opposite portions of the edge of the package; 5) wherein the surface can accommodate a plurality of flexible packages at different positions; 6) variation (3) wherein the storage device further comprises controllable retaining means for flexible packages stored at different positions within the device.
In a ninth aspect of the invention a method for dispensing an ingredient from within a package into a receptacle beneath the package, includes: (a) relatively lowering the ingredient to make contact with the receptacle; (b) relatively moving the receptacle in a direction that causes at least a portion of the ingredient to change its orientation; (c) allowing the ingredient to exit the package and enter the receptacle.
Numerous variations of the ninth aspect of the invention are possible and include, for example wherein the ingredient has a first side and a second side and wherein the receptacle is moved in a direction to controllably cause the first side to face upwards when the ingredient has at least partially entered the receptacle.
In a tenth aspect of the invention a method for dispensing an ingredient onto a substrate, includes: (a) allowing or causing an ingredient to relatively descend toward a substrate; (b) relatively moving the substrate in a direction that causes the ingredient to rotate as it descends further; wherein the ingredient is laid onto the substrate in a desired orientation.
In an eleventh aspect of the invention a chain of continuously-joined flexible packages for storing and dispensing a plurality of items, includes: (a) at least one continuous flexible film having a longitudinal axis and comprising a left portion and a right portion and wherein the portions are at least partially sealed to one another to form a plurality of individual compartments each holding at least one item; (b) an openable seal adjacent to each compartment and oriented at an angle smaller than 90 degrees to the longitudinal axis.
Numerous variations of the eleventh aspect of the invention are possible and include, for example: 1) wherein the orientation of the seal is substantially parallel to the longitudinal axis; 2) further comprising at least one flap adjacent to each openable seal; 3) further comprising reduced-strength features proximate at least some compartments selected from the group consisting of i) perforations and ii) scores.
In a twelfth aspect of the invention a method for manipulating a flexible package comprising flaps, the method includes: (a) providing a flexible package wherein the package comprises at least one flexible film comprising a left portion and a right portion with each portion having an inside and an outside surface with the inside surfaces facing each other and wherein the portions are partially sealed to one another and wherein each portion comprises an unsealed flap; (b) inserting the flaps between a pair of counter-rotating rollers; then (c) engaging clamping means to clamp each flap against the surface of one roller; then (d) separating the two rollers and two flaps from one another.
Numerous variations of the twelfth aspect of the invention are possible and include, for example: 1) further comprising unsealing at least a portion of the seal; 2) further comprising providing attracting means for attracting each flap to one roller; 3) variation (1) wherein the attracting means is selected from the group consisting of i) vacuum, ii) adhesive material, iii) microstructured adhesive, and iii) electrostatic attraction.
In a thirteenth aspect of the invention a device for grasping a flexible package having at least one edge and transporting the package between locations, includes: (a) grasping means for grasping an edge of the package; (b) rotating means for rotating the package around a substantially horizontal axis from an initial orientation to a final orientation.
In a fourteenth aspect of the invention an automated method for preparing food using a plurality of ingredients, includes: (a) readying a plurality of ingredients by transferring the ingredients from at least one storage device to at least one temporary holder using first mechanical grasping and relocating means; (b) grasping and transferring an ingredient from the temporary holder to a dispenser as needed using second mechanical grasping and relocating means; (c) dispensing the ingredient into a receptacle.
Numerous variations of the fourteenth aspect of the invention are possible and include, for example: 1) wherein first mechanical grasping and relocating means and second mechanical grasping and relocating means are the same; 2) wherein first mechanical grasping and relocating means and second mechanical grasping and relocating means are not the same; 3) further comprising altering the temperature of an ingredient within the at least one temporary holder.
In a fifteenth aspect of the invention an automated system for preparing food from ingredients contained in packages, includes: (a) storage means for storing a plurality of packages; (b) heating means for heating ingredients within packages; (c) automated transfer means configured to transfer packages from the storage means to the heating means; (d) automated dispensing means; (e) automated transfer means configured to transfer packages from the heating means to the dispensing means.
Numerous variations of the fifteenth aspect of the invention are possible and include, for example wherein the heating means is selected from the group consisting of i) a hot liquid bath, ii) a convection oven, iii) a microwave oven, iv) an infrared heater, v) a solid-state radio frequency (RF) oven, vi) hot air, and vii) steam.
In a sixteenth aspect of the invention a method for automatically disposing of an empty or unusable flexible ingredient package, includes: (a) grasping the package with a mechanical grasper; (b) repositioning the package above a waste container; (c) releasing the package from the grasper into the container.
In a seventeenth aspect of the invention a method for preparing food for a food consumer, wherein the food requiring both heated and non-heated ingredients, includes the consecutive steps of: (a) dispensing at least one ingredient into a receptacle; then (b) heating the at least one ingredient within the receptacle; then (c) dispensing at least one additional ingredient into the receptacle; (d) conveying the receptacle to a food consumer.
In an eighteenth aspect of the invention a flexible package for storing and dispensing a plurality of ingredients, includes: (a) at least two compartments arranged one above the other when the package is oriented for dispensing; (b) a peelable seal below each compartment, the peelable seal comprising at least one non-horizontal region.
In a nineteenth aspect of the invention an apparatus for dispensing the contents of an upright flexible package comprising two film regions and an openable seal between the two film regions located below the contents of the package wherein the flexible package further comprises extensions of the films below the seal, the apparatus includes: (a) actuated gripping means configured to grip the package along two opposite vertical edges in locations proximal to or lower than the openable seal; (b) actuated moving means configured to move the gripping means in opposite directions to horizontally tension the lower portion of the package and the extensions; (c) actuated grasping and tensioning means for grasping the extensions and tensioning them to open the seal.
In a twentieth aspect of the invention a method for unsealing and dispensing a flexible package having an openable seal and flaps extending below the seal, includes: (a) orienting the package upright with the openable seal toward the bottom of the package; (b) grasping the package along two opposite vertical edges; (c) pulling the two edges in opposite directions.
Numerous variations of the twentieth aspect of the invention are possible and include, for example wherein the peelable seal has the shape of a chevron having an apex at the bottom, and wherein the package is grasped at a height substantially equal to or lower than the height of the apex.
In a twenty-first aspect of the invention a method for dispensing a food ingredient from a package, includes: (a) providing a sealed package containing a food ingredient wherein the package comprises at least one flexible film comprising a left portion and a right portion with each portion having an inside and an outside surface with the inside surfaces facing each other and at least a portion of the inside surfaces contacting the ingredient and wherein the portions are sealed to one another to form at least one cavity containing the at least one ingredient and wherein adjacent to the at least one ingredient, the sealing comprises at least one openable region and wherein the package comprises two opposite edges and two unsealed flaps beneath the seal; (b) gripping the package near the two edges and pulling outwardly on the package to apply tension to it; (c) separating and reorienting the flaps; (d) clamping the flaps and applying tension to them; wherein the package is opened.
Numerous variations of the twenty-first aspect of the invention are possible and include, for example wherein the seal comprises a chevron having an apex at its bottom and wherein the gripping is substantially at or lower than the height of the apex.
In a twenty-second aspect of the invention a device for applying tension to at least one portion of a sealed flexible package (e.g. a flap portion) to open the package and dispense the contents from within the package, includes: (a) a moveable upper clamp configured to move along an upper clamp path and comprising an upper clamping surface configured to contact a portion of a flexible package from above; (b) a moveable lower clamp below the upper clamp configured to move along a path at least partly common with the upper clamp path and comprising a lower clamping surface configured to contact the portion from below; (c) movement means to move at least one of the upper clamp and lower clamp while the portion contacts upper and lower clamping surfaces.
Numerous variations of the twenty-second aspect of the invention are possible and include, for example: 1) further comprising guiding means to guide the upper and lower clamps to move at least partially along the upper clamp path; 2) further comprising urging means to urge the upper clamp downward against the portion, wherein the urging means is selected from the group consisting of i) weight, ii) mechanical spring, iii) gas spring, iv) at least one magnet, v) at least one electromagnet, vi) at least one electropermanent magnet, vii) electrostatic element, and viii) adhesive; 2) further comprising support means configured to prevent the upper clamp from descending as low as the lower clamp; 3) further comprising at least one blade having a lower edge around which a portion of a flexible package is partially wrapped and redirected; 4) further comprising a high friction material on the upper and lower clamping surfaces.
In a twenty-third aspect of the invention a method for applying tension to portions of a flexible package to open the package, includes: (a) providing a moveable upper clamp able to move along an upper clamp path and having an upper clamping surface configured to contact a portion of a flexible package from above; (b) providing a moveable lower clamp below the upper clamp able to move along a path at least partially in common with the upper clamp path and having a lower clamping surface configured to contact the portion of the flexible package from below; (c) introducing a portion of a flexible package into the space between upper and lower clamping surfaces; (d) moving at least one of the upper or lower clamps until the portion of the package contacts both upper and lower clamping surfaces; e) moving the upper and lower clamps in a direction that applies tension to the portion thereby opening the package.
In a twenty-fourth aspect of the invention a dispenser for a flexible package, includes: (a) two substantially symmetric and aligned pouch unsealing and dispensing subsystems facing one another; (b) mechanical means for increasing the gap between the subsystems and for decreasing the gap while maintaining alignment of the two subsystems.
In a twenty-fifth aspect of the invention a flexible package containing at least one substance, includes: (a) at least one flexible film comprising a left portion and a right portion and wherein the portions are partially sealed to one another to form at least one compartment containing the at least one substance; (b) a seal comprising at least one openable region; (c) an unsealed extension of at least one portion of the film; (d) at least one region within the at least one unsealed extension having apertures to allow passage of pushing means.
Numerous variations of the twenty-fifth aspect of the invention are possible and include, for example wherein left and right extensions are provided, with each extension including an aperture, and wherein the apertures of the left and right extensions are in different relative locations.
In a twenty-sixth aspect of the invention a method for manipulating a flexible package comprising unsealed extensions, the method includes: (a) providing a flexible package wherein the package comprises at least one flexible film comprising a left portion and a right portion and wherein the portions are partially sealed to one another and wherein each portion comprises an unsealed extension having an aperture; (b) pushing on a left portion extension by passing pushing means through the aperture of the right portion extension; (c) pushing on the right portion extension by passing pushing means through the aperture of the left portion extension; whereby one extension is separated from the other.
Numerous variations of the twenty-sixth aspect of the invention are possible and include, for example reorienting the extension sufficiently to allow it to be clamped by clamping means.
In a twenty-seventh aspect of the invention a method for automatically emptying an ingredient within a flexible ingredient package into a vessel and disposing of the package, includes: (a) grasping the package with a grasper; (b) dispensing at least a portion of the ingredient into a vessel located beneath the package and overlying a waste container; (c) relatively positioning the vessel so it is no longer located beneath the package or overlying the waste container; (d) releasing the package from the grasper and allowing the at least partially emptied package to fall into the waste container.
In a twenty-eighth aspect of the invention a method for manufacturing a flexible package, includes: (a) providing first and second flexible films; (b) forming aligned apertures in first and second films while the two are in proximity; (c) feeding the first film toward a sealer along a first path; (d) feeding the second film toward the sealer along a second path longer than the first path; (e) sealing together the two films; whereby a flexible package is produced wherein the location of the apertures in the first film and the second film are not aligned.
In a twenty-ninth aspect of the invention a method for opening a flexible package, includes: (a) providing a package having two flaps with non-aligned apertures; (b) inserting pins through the apertures of the flaps; (c) moving the pins to separate the flaps; whereby the package is opened.
Numerous variations of the twenty-sixth aspect of the invention are possible and include, for example grasping the separated flaps and applying tension to them.
In a thirtieth aspect of the invention a method for opening a flexible package, includes: (a) providing a package having first and second flaps each with apertures; (b) inserting a first pad through the aperture in the first flap; (c) clamping the second flap between the first pad and a second pad; (d) inserting a third pad through the aperture in the second flap; (e) clamping the first flap between the third pad and a fourth pad; (f) the pads to separate the flaps; whereby the package is opened.
Numerous variations of the thirtieth aspect of the invention are possible and include, for example wherein grasping the flaps further comprises tensioning the flaps.
In a thirty-first aspect of the invention a method for heating an ingredient, includes: (a) providing an ingredient within a first pouch; (b) providing a second pouch that surrounds the first pouch; (c) opening the second pouch to expose the first pouch; (d) heating the ingredient through the first pouch; (e) opening the first pouch to remove the heated ingredient.
In a thirty-second aspect of the invention a method for heating an ingredient, includes: (a) arranging two plates with inner surfaces facing one another and separated by an angle between zero and 180 degrees; (b) dispensing an ingredient onto the inner surface of at least one plate; (c) moving at least one plate until the inner surfaces are substantially parallel; (d) heating at least one plate; (e) separating the plates; whereupon the heated ingredient leaves the plates and enters a receptacle.
Numerous variations of the thirty-second aspect of the invention are possible and include, for example: 1) further comprising covering the at least one plate with a heat-resistant cover; 2) wherein the cover is retained by vacuum.
In a thirty-third aspect of the invention an automated method for supplying a meal, includes: (a) receiving an order; (b) providing a receptacle; (c) providing flexible packages containing ingredients; (d) determining from the order the ingredients required and the packages containing them; (e) successively dispensing the required ingredients from the identified packages into the receptacle; (f) heating or cooling ingredients which requires heating or cooling.
In a thirty-fourth aspect of the invention an apparatus for automated food preparation, includes: (a) storage means for storing flexible packages each containing at least one ingredient; (b) grasping means configured to grasp the packages; (c) a dispenser configured to unseal each package and dispense the at least one ingredient; (d) a receptacle configured to receive the at least one ingredient from each package; (e) positioning means for moving the packages to the dispenser; and (f) a container for depositing each at least partially empty package.
Numerous variations of the thirty-fourth aspect of the invention are possible and include, for example: 1) wherein the storage means comprises a plurality of cubbies; 2) wherein the grasping means comprises a gripper configured to grip each package at its upper edge; 3) wherein the dispenser comprises moving clamps configured to grasp and apply tension to a portion of each package to open it; 4) wherein the clamps are configured to grasp flaps of the package; 5) wherein the dispenser comprises a blade having an edge around which flaps of the package are partially wrapped.
In a thirty-fifth aspect of the invention a method for automated food preparation, includes: (a) providing a flexible package containing at least one ingredient; (b) providing a motion stage, a dispenser, and a receptacle below the dispenser; (c) grasping a first portion of the package; (d) moving the motion stage to position the package in proximity to the dispenser; (e) grasping at least a second portion of the package; (f) opening the package to discharge the at least one ingredient into the receptacle.
Numerous variations of the thirty-fifth aspect of the invention are possible and include, for example: 1) wherein the opening comprises peeling a peelable seal of the package; 2) wherein the opening further comprises substantially peeling apart two walls of the package.
In a thirty-sixth aspect of the invention a flexible package for cooking a food item, includes: (a) a food item compartment enclosed by a heat-resistant material; (b) a permeable support below the food item compartment; (c) a liquid compartment below the permeable support; (d) a grease-absorbing filter above the food item compartment; (e) at least one openable seal.
In a thirty-seventh aspect of the invention a storage device for a plurality of flexible packages, includes: (a) a flexible package support comprising a plurality of substantially coplanar tilted surfaces; (b) an individually-controllable vibration means coupled to each tilted surface; (c) a stop at the lowest end of the device.
In a thirty-eighth aspect of the invention a method for fabricating a perforated flexible package from two continuous webs of film, includes the steps of: (a) providing a first and a second web of film; then (b) perforating the first and second film; then (c) advancing the first film towards sealing means along a part of length A while advancing the second film towards sealing means along a path of length B where B is greater than A; then (d) sealing the first and second film together to form a package.
In a thirty-ninth aspect of the invention a flexible package for self-contained cooking of an ingredient contained therein, includes: (a) at least two flexible films each having a bottom and a top edge; (b) a cavity for an ingredient; (c) an openable discontinuous seal between the films below the ingredient cavity; (d) a cavity for liquid below the seal; (e) a first openable seal between the films below the cavity for liquid; (f) a second openable seal between the films above the ingredient cavity; (g) filtration material above the second openable seal; (h) at least one aperture in at least one film above the second openable seal.
Numerous variations of the thirty-ninth aspect of the invention are possible and include, for example wherein at least a portion of at least one film is heat resistant.
Numerous additional variations of the aspects are possible and may include for example, variations associated with one aspect of the invention being applied to other aspects. Other aspects of the invention will be understood by those of skill in the art upon review of the teachings herein. Other aspects of the invention may involve combinations of the above noted aspects or variations of aspects of the invention. It is intended that variations of one aspect of the invention may be applied to other aspects of the invention and that various features of one or more aspects of the invention be useable in other aspects of the invention and even that sub-combinations of various features of one or more aspects of the invention may provide new aspects of the invention. Combinations are considered appropriate so long as the combinations do not remove all functionality provided by individual components. These other aspects of the invention may provide various combinations and sub-combination of the aspects presented above as well as provide other configurations, structures, functional relationships, processes for making, and/or procedures for using that have not been specifically set forth above.
Pouches and Other Containers, Ingredients
Dispensing of ingredients from containers by simply tilting/inverting the container, or providing a passage through the container bottom—and relying on gravity alone—can be very inefficient for many ingredients (i.e., a significant percentage of the container contents will remain in the container after dispensing), and often involves contamination of system components. Key problems associated with automated food preparation may be addressed by providing ingredients in containers or packages which can be handled by suitable apparatus, processes, and algorithms in various embodiments of a food preparation system. In this regard, properly-designed flexible packages (hereinafter typically called “pouches”) are particularly advantageous in terms of ingredient quality (e.g., freshness), food safety, and the wide variety of ingredients that can be stored and dispensed (e.g., low, medium, and high-viscosity liquids; solids; powders; gels; pastes; moist solids; liquid/solid mixtures; and gases). Among the benefits of pouches over alternative packages such as hoppers and other rigid containers are: 1) low cost; 2) compact (small overall volume; can be stored closely together, especially when empty) and lightweight; 3) environmentally friendly, using less material and often fully recyclable; 4) easily made in different sizes and shapes; 5) can serve as pulseless, peristaltic-like pumps to dispense flowable ingredients without contact over a wide range of viscosities; 6) can be evacuated, provided with barrier layers, and filled with gasses to prolong shelf life, avoid oxidation, etc.; 7) can easily be opened by cutting, peeling, etc.; 8) can be opened to their full width to release large items; 9) allows ingredients to be cooked (e.g., sous vide), warmed, or cooled within the pouch; 10) can be subdivided into compartments; 11) easily sealed, can be re-sealed if desired; 12) allows “on the side” ingredients such as salad dressing to be delivered directly to customers in convenient form; 13) can be used for in-pouch processing such as coating (e.g., with breadcrumbs), mixing, beating, blending, marinating, and other operations involving multiple ingredients (e.g., a pouch containing fish can be emptied into another pouch containing a coating mix which is then sealed and tumbled); 14) if pouches contain just a single serving/portion, allows exact portion control, perfect inventory tracking and traceability, and removal of expired product without contaminating other product; and 15) enables novel and inventive designs allowing dispensing that is non-contact and efficiently discharges virtually the entire ingredient from the pouch (e.g., by passing the pouch around a blade).
A representative pouch used in some embodiments of the invention and able to contain one or more food ingredients, a fully-prepared meal, etc. is shown in an upright orientation in
As constructed, the pouch of
Pouches may have complex constructions. For example, a pouch intended to dispense an ingredient consisting of small pieces (e.g., a powder) may comprise an inner pouch 16 as in the 3D view of
Perforated or gas-permeable pouches may be used to allow respiration for certain ingredients (e.g., spring mix lettuces, celery, cucumbers, tomatoes, bananas, broccoli, leeks) and/or provide drainage of excess moisture to prevent spoilage. If perforated, very small holes/micro-perforations (e.g., 5-300 microns diameter) may be desirable to control respiration (e.g., one or more 100-micron holes in a pouch) but also to minimize the risk of contaminants and/or insects from entering the pouch or ingredients escaping. Such perforations can be produced by lasers or mechanical perforating techniques known to the art. Alternatively, at least a portion of the pouch may comprise a woven, nonwoven, or mesh material.
A variety of food items (single ingredients or combinations thereof) may be dispensed from a pouch whose inner surfaces are non-wettable (e.g., superhydrophobic, using the technology of LiquiGlide, Cambridge, Mass.). If the intent is to dispense the ingredient fully and as quickly as possible into a receptacle (e.g., dish or vessel) as is typically the case, such dispensing may consist essentially of opening the pouch at its bottom and allowing the item to fall out. However, without superhydrophobic surfaces, which may be too costly especially for single-use pouches, or for more controlled dispensing, novel apparatus and methods as described herein are favorably employed.
Food items may be classified as Type 1, 2A, or 2B, and dispensed efficiently, depending on their properties, using one or more of three optimal approaches, though non-optimal dispensing of a particular ingredient may also be implemented (e.g., if the optimal approach is not available). Type 1 items are flowable with a wide range of viscosities; these can be dispensed very effectively in some embodiments by methods and apparatus that implement a peristaltic squeezing/displacement/expressing approach in which i) the pouch is opened at the bottom (fully or partially); and ii) pressure is applied to the flexible walls of the pouch either generally to compress them, or to locally compress the walls and move the region of compression downwards, displacing the pouch contents toward the opening (or through an extrusion nozzle, if provided). In some cases in which the pouch is sealed with a peelable/burstable seal at its bottom and with a suitable ingredient, step i) is not needed, since pressure buildup within the pouch will open it, but this should be well-controlled. Flowable items include a wide variety of liquids ranging from oil to nut butters to guacamole, and are not limited to pure liquids, gels, or pastes, in that they may contain solids combined with a volume of liquid sufficient to allow the item to flow. Type 2A and 2B items, in contrast, are not particularly flowable, and would more likely be crushed than dispensed if pressure were applied to the pouch with the item inside. Type 2A items may be relatively heavy, large, with small surface/volume ratios, and/or are dry, and do not tend to adhere to the pouch inner walls, while Type 2B items may be relatively light, small, have larger surface/volume, and/or are moister, and tend to adhere to the walls. These tendencies are influenced by the state of the ingredient and the composition and condition of the walls, such as their surface energies. Type 2A ingredients may be dispensed in some embodiments by merely opening the pouch and letting them fall out (however, the pouch may be shaken, jerked, accelerated, or vibrated (e.g., by the gripper(s) holding it) in a controlled way so as to promote dispensing but avoid dispersing the item anywhere than intended (e.g., outside a dish, where it could contaminate the system)). Examples of type 2A items include many nuts and iceberg lettuce. However, if this simple approach is attempted for type 2B items (e.g., canned tuna, beans, sautéed vegetables), a significant fraction of the item will typically remain in the pouch, leading to waste, the risk of an unpleasant odor if the item starts to spoil, attractiveness to vermin, and more difficult pouch recycling.
According to some embodiments, type 2B items can be very effectively dispensed by methods and apparatus which peel the walls of the pouch completely apart, such that the item within loses the support of the walls and falls. Depending on size, shape, moisture content, etc., this may be adequate to dispense them. For more challenging items or portions thereof, additional methods and apparatus can be applied to ensure efficient and complete dispensing such as ensuring that 1) the angle between the walls as they are peeled apart is optimal, and 2) providing for one or more blades (as in FIG. 27(c′) of the 074 and 253 filings) having a small radius of curvature at its lower edge around which the firm forming the walls of the pouch can be wrapped, and ensuring that the plane of each film changes its angle (is redirected) significantly as it passes over the edge. It has been observed that items which are small, moist, high surface/volume and/or lightweight and which initially adhere to the film usually cannot negotiate the tight turn as the film advances around the blade, due to such properties as stiffness, and therefore fall off the film as desired. Thus, according to some embodiments, a given food item may be classified according to the best method of dispensing it, and the appropriate method and/or apparatus selected. For example, if an item is classified as Type 1, squeezing the pouch may be selected as the preferred dispensing approach (e.g., for efficiency and speed) rather than just opening the pouch, which may not work well if ingredients tend to adhere to the walls, or opening and peeling the pouch. If the item is type 2B, then peeling the pouch entirely apart and passing the films of which it is comprised over blades as in FIG. 27(c′) of the 074 and 253 filings may be selected as the preferred dispensing approach. In contrast, pouches for Type 1 or 2A ingredients may not be easily openable except in region 14 (
In some embodiments certain regions of the pouch seal are made weaker and/or faster-yielding than others. This can be useful so as to allow peeling only in certain regions (e.g., the chevron portion of the seal) while preventing it in others (the sides of the pouch), to allow peeling of an internal seal (e.g., between compartments) but not external seals (separating ingredients from the environment), allowing the pouch to vent in a desired location in case pressure builds up internally (e.g., due to steam and air heating while the pouch is heated). Variations in seal strength can be achieved by methods including a) applying two or more sealant materials to the film used in making the pouch; b) applying a sealing inhibitor to certain regions of the pouch; c) weakening the seal in certain regions by lightly sealing it to a temporary surface which is then peeled off or using a seal material that can be weakened (e.g., by exposure to radiation); d) varying the sealing temperature or pressure in different regions by i) using sealing dies which are differentially heated, ii) using dies having surface topography (some surfaces of the die being lower than others to reduce contact pressure), iii) sealing with a die of variable hardness (e.g., comprising silicone rubber or other temperature-stable elastomer, possibly filled to enhance thermal conductivity), or iv) sealing against a platen comprising materials of variable hardness (e.g., elastomers of two different durometers); e) using a die comprising multiple pieces and/or flexible elements, such that certain regions can be left in contact with/press against the film for a longer time than others; and f) sealing certain regions more than a single time.
In some embodiments it is desirable that the force required to peel the pouch be fairly constant, for example, in order to better control the tension of the pouch during peeling, which affects the bending radius of the pouch film as it passes around the blade (smaller bending radii improve ingredient detachment from the film). The required force at any moment in time during peeling is normally proportional to the width of the seal being peeled at that time. If the seal has a chevron design such as in region 14 of
In some embodiments the film of which an ingredient pouch is made can also be a flexible circuit. With suitable design, such a circuit may allow measurement of temperature, freshness, pouch distortion, fill level, weight, internal pressure (which may indicate leaks or spoilage), etc. The circuit can incorporate built-in strain gauges, capacitive sensors, RFID, vibration sensing, and other elements such as batteries, antennas, data logging circuitry, and GPS. The status of the pouch can be determined from a distance or in contact with it, using for example near field communication, backscatter radio/RFID, passive or active RFID, etc. Using appropriate circuitry, the status and entire history of the pouch from the time it is fabricated (or the ingredient packaged) to the time at which it is opened can be determined.
In some embodiments, especially for Type 1 and 2A ingredients, pouches may be designed to break in a well-controlled way when forces are applied; this may be used in some embodiments in lieu of peeling them to open them. For example, in the cross-sectional elevation view of
The rate at which a Type 1 ingredient leaves the pouch—especially if low viscosity—may be controlled (e.g., eliminating spontaneous dripping so that flow rate is entirely controlled by squeegee motion and can be made consistent) by including a tube (e.g., rigid or semi-rigid plastic, preferably of the same material as the pouch, for recyclability) or similar shape in the pouch, around which the pouch is sealed (peelably or non-peelably) along the upper sides of the tube, such that the inside of the pouch communicates with the inside of the tube. This is depicted in the 3D view of pouch 50 in
Pouches in some embodiments may be formed from combinations of metal foil or vacuum-deposited metal with paper or polymer. For example, parchment paper (on the inside surface of a pouch) laminated to aluminum foil, can allow cooking with a conduction heat source, even of foods that might not be too compatible with aluminum. Or, a pouch may comprise a polymer sealed to two elements (e.g., rectangles) of metal foil that are adjacent to an ingredient within. Thus, the polymer elements of the pouch can provide robustness and a peelable seal, while the metal elements allow the ingredient to be heated/cooked by contacting the foil elements with a heated plate, etc.
Peelable pouches may comprise two peelable films (e.g., heat sealable) sealed with the sealing layers of the films in face-to-face contact. Alternatively, they may comprise a single peelable film in contact with a plain film (e.g., polyester, polyethylene, polypropylene, nylon) or other substrate (e.g., paper, metal foil, TYVEK®). The second case may be advantageous in some embodiments in that it allows the plain film to be optimized for another function, such as printability, opacity, color, mechanical and barrier properties, etc. Moreover, the second case may provide for greater seal uniformity and lessen the risk of shredding the film(s). Since heat sealable coatings may not be perfectly uniformly dispersed and there can therefore be local, random variations, when two such films are bonded, there may be regions having little sealable material, and regions having an excess of sealable material. The former regions may bond poorly, potentially allowing pouch rupture at low pressure, while the latter regions may bond too strongly, initiating a tear in the film(s).
Manufacturing pouches which are both recyclable and have the desired mechanical and/or barrier properties is currently a major challenge for the packaged food industry, since films with the desired properties typically are laminated from multiple layers of different materials which are difficult/impossible to separate for recycling. In some embodiments, a pouch may be produced from multiple materials which are not laminated across their entire surface as usual, but only at the edges or in other specific locations. While such a pouch may not have the same mechanical properties as a laminated pouch, its barrier properties are similar. To recycle such a pouch, one need only trim away the laminated regions; the unlaminated regions, comprising the majority of the material, then separate and can be easily recycled.
In some embodiments, a pouch that is at least partially peelable may be made from a two-layer film in which both layers may be the same material (for recyclability) or different (e.g., a metallized coating on the inside surface of the films. The strength of the peelable seal can be made to be less than that of the bond between the two layers (such that the pouch normally will peel into two pieces) but should not be excessive. Then, if the pouch begins to tear/shred, rather than the entire film tear through as can happen with a one-layer film, the inner layer will separate and remain with the film on the other side of the pouch.
Providing an intentionally weak region of a seal to allow venting of the pouch is possible as discussed, and such a region may preferably be located in the upper portion of the pouch. In some embodiments it is desirable to prevent the escape (or entrance) of anything other than fluids, in which case small perforations, or an incorporated piece of TYVEK®, GORE-TEX®, woven or nonwoven cloth, or screening can be incorporated downstream of the weak region of the pouch as a barrier.
In some embodiments a pouch might use a zipper(s) such as those found in ZIPLOC® bags in lieu of or in addition to a peelable seal.
In some embodiments the pouch can comprise a liquid-absorbing material to absorb liquids from ingredients (e.g., meat, fish). This material is preferably retained in the pouch by being fastened to it, by being located in a separate compartment, etc. In some embodiments the pouch comprises both a primary compartment for the ingredient, and a separate “capture” compartment into which excess liquids can drain. In some embodiment variations, the pathway to the capture compartment is equipped with a check (one-way) valve, which may for example comprise a flap of the material of which the pouch is made which overlies a hole in the primary compartment, and which prevents liquid from returning to the primary compartment. In some embodiment variations, the capture compartment contains a liquid-absorbing material.
Ingredients within pouches may include those that are fresh, frozen, freeze-dried, dehydrated, partially dehydrated, high pressure processed, irradiated, aseptically packaged, etc. Freeze drying, dehydration, etc. allow for larger amounts of food to be provided from small pouches, and reduces weight that needs to be transported when restocking the apparatus. Water or other liquids can be added either from pouches, tanks/reservoirs inside the system, from a water supply outside the system, etc. Unlike food, water if pure (e.g., filtered, UV-sterilized) cannot contaminate components of the machine if in contact with them, and so need not be kept from contacting them.
Many ingredients can be stored in a frozen state and defrosted as needed. For example, ingredients in a pouch containing minimal air can be defrosted (and also heated and/or cooked, if desired) by immersion in warm or hot liquid such as water. While this process can take some time, it is suitable for ingredients comprising a pre-ordered meal, or a meal consumed in quantity during peak hours. Based on historical demand, a number of pouches can be processed this way, even simultaneously. Reheating in water, as well as cooking sous vide, is not affected significantly by total heating time, so ingredients in pouches removed from a bath at different times will be comparable.
Growing Ingredients
Ingredients need not be supplied to automated food preparation apparatus in the state in which they will be used. For example, ingredients can grow (e.g., lettuce), sprout (e.g., mung beans), ferment (e.g., yogurt, kefir), soften (e.g., beans soaked in water), age (e.g., cheese), marinate (e.g., steak immersed in marinade), rise (e.g., bread dough), be ground (e.g., coffee or flour), etc., all within the machine.
Produce can be grown within the automated food preparation machine using techniques such as hydroponics, aeroponics, and sprouting. If produce is grown this way, it can be extremely fresh and flavorful since it can be harvested immediately before consumption and does not require pesticides. Moreover, washing of ingredients can be eliminated and the effort and expense of restocking the machine can be reduced, since ingredients not yet harvested remain fresh for extended periods; produce restocking only then requires transporting small, lightweight items such as seeds. Ingredients may be grown within pouches at least partially. For example, a hydroponic/aeroponic nutrient solution may be inside a pouch along with the plant roots, while outside the pouch the rest of the plant grows. Or, a two-compartment pouch might include a lower compartment for nutrient solution, and a permeable (e.g., perforated) upper compartment for the remainder of the plant. Ingredients may also be grown in other containers than pouches (e.g., rigid containers), and may be grown in large contiguous quantities or small, isolated quantities. Appropriate growing media such as sponges made from peat, rockwool, etc. can be used (e.g., incorporated into pouches or other containers). In some embodiments the normal growing arrangement (roots at the bottom) may be modified (e.g., locating roots at the side, roots at the top) so as to facilitate harvested ingredients falling into a dish or vessel below. In some embodiments crops are grown in the normal orientation (roots at the plant bottom, receiving nutrient solution (e.g., via spray) and receive light from above), but at least some crops are temporarily rotated to another orientation (e.g., horizontal, inverted) during harvesting so that harvested ingredients fall without needing to be touched into a serving dish or other vessel. It may be desirable in some embodiments that an ingredient is grown in fairly small volumes and weights that are portion/serving-sized, thus minimizing the need to cut apart the ingredient into smaller units. However, such processing may still be desirable: lettuce leaves, for example, can be trimmed in their upper extremities, or individual leaves can be cut at the stem.
In some embodiments ingredients may be grown on a continuous translating or rotating surface such as a conveyor belt, dish, or drum, having the properties required to support the plant (e.g., open porosity). If needed (e.g., for fruits) pollen can be dispersed within the growing environment. Lighting (e.g., LED lighting with optimized spectral characteristics) can be provided, and customized for each growing ingredient, as can temperature and humidity. Automated, robotic pruning/harvesting mechanisms may be used in some embodiments, and in some embodiments, ingredients may be induced/constrained to grow in particular shapes and forms by the apparatus, so as to improve growing conditions, facilitate harvesting, etc. In some embodiments ingredients may be detached from their roots when ready to harvest, or cut higher up, by automated cutters or other automated mechanisms that pluck, shear, break, tear, twist, crush, or otherwise process the plant in order to isolate the desired portion of the ingredient from portions that are not to be consumed at the time (or ever: these can be collected for composting, etc.) Methods of cutting can include laser (e.g., excimer or femtosecond lasers which ablate the plant material without burning), high-pressure waterjet cutting, ultrasonic cutting (e.g., a blade coated with a disposable film, or a disposable or cleanable tensioned vibrating wire), a saw blade, string, or cable (similar to a string trimmer used in gardening), etc.
Harvested ingredients can be transported (e.g., by falling directly) from the location in which they're grown to a dish for serving, or to a vessel for further processing. Ingredients not used soon after harvesting can be kept reasonably fresh by spraying regularly with water, etc.
In some embodiments, machines for automated food preparation can include bioreactors or similar apparatus allowing cultured meat, fish, or poultry to be grown within the machine, e.g., within portion-sized pouches, molds, or other containers.
First System
Pouch chains that move horizontally (e.g.,
Dispensers such as those of
Individual Pouch Dispensing
The function of the dispenser is to dispense ingredients from pouches efficiently, i.e., to eject as much of the pouch contents as possible, do so quickly (e.g., in 2-3 seconds), and do so with hardware that is as simple and inexpensive as possible. Moreover, the subsystem should be able to dispense an ingredient without physically contacting it, such that the ingredient only contacts the inner surface of the pouch/strip and does not contaminate any portion of the machine, thus obviating the need for cleaning (whether in-situ or after removal) or replacement.
In machines having multiple types of dispenser, the controller (computer, microcontroller, etc.) may select the appropriate type of dispenser for a given ingredient.
In
The squeezer, used for Type 1 food items, serves to impinge a squeegee, roller, or similar (hereinafter “squeegee” unless noted) against the wall of the pouch and move downwards toward the pouch opening, pushing out the item. The squeezer may be designed so the squeegee can retract away from the pouch (e.g., to allow it to be loaded). In the embodiment shown, the squeezer achieves movement to and away from the pouch, and downwards movement economically, with a single motor as actuator. The squeezer may comprise tilting squeegee 80 which tilts around pivot 82 and has inner working end 84 that contacts the pouch outer wall, upper member 86, lower member 88, at least one guide rod 90, lead screw 92 and nut 94 fixed to the upper member. It may further comprise standard items known to the art such as a motor to turn the lead screw, power transmission components (e.g., gears, pulleys) connecting the motor and lead screw, various brackets to support motor and guide rod(s), a spring (not shown) or similar (e.g., compression, gas, constant force, cable passing over a pulley connected to a weight) that urges lower member 88 upwards, and an optional spring that tilts the working end of the squeegee down, none of which are shown. The squeegee may also be weighted so it normally tilts down without a spring. The upper member comprises a boss 96 at its bottom that can press on the on the end of the squeegee opposite its working end to tilt the squeegee, and bushings/bearings that allow it to slide on the guide rod(s). The lower member comprises a stop 97 which prevents the squeegee from tilting past a certain point, and bushings/bearings surrounding the guide rod(s). The squeegee may have relief 98 to allow its working end to tilt downwards without the squeegee interfering with the lead screw; a relief in the lower member (shown) may also be provided if needed. Both the upper and lower members are able to slide on the guide rod(s).
As shown in the elevation view of
In some embodiments only one squeezer is used, and a substantially rigid plate adjacent to the opposite wall of the pouch is provided. Then, the single squeegee generates the force needed to dispense the item after tilting to squeeze both pouch walls between its working end and the plate. In some embodiments in lieu of one or more moving squeegees, one or more inflatable bladders 102 are used as shown in the elevation views of
The peeler can be seen in
The upper and lower clamps are designed to not interfere with the motion of at least two vacuum cups connected to a vacuum source which may be provided to engage/couple to/grasp the pouch flaps so as move them toward the clamps. Alternatives to vacuum cups include temporary and reusable adhesives, electrostatically-attracted pads, suction cup tape (Inventables, Chicago, Ill.), microstructured adhesive (e.g., SETEX™ (nanoGriptech, Pittsburgh, Pa.)), and expanding elements which enter holes in the flaps. Vacuum cups 85 may be circular as shown in
Vacuum cups 85 may be mounted on moveable supports driven by actuators, neither shown, allowing them to move the flap, once it is grasped, toward the clamps. In the embodiment shown, the vacuum cup moves in a circular path that is approximately centered on the upper edge of the flap, such that the flap need not slide vertically relative to the cup as the cup reorients it. The moveable cup supports can be a simple arm to the side of the dispenser, driven by a stepper motor or rotary solenoid, for example. The arm may also serve to conduct vacuum to the cup, or tubing can be used, etc. In some embodiments the cups holding a given flap may be moved outwards (i.e., away from one another) as well, e.g., before or while moving the flap toward the clamp, which can help stretch (if the material is elastic) or at least tension and flatten the flap, since the flap may be distorted by the contents of the pouch. Simultaneous rotating and outwards movement may be achieved by using a lead screw (e.g., with a high pitch) and nut to rotate and translate the cups: lead screws on opposite sides of the dispenser may therefore have opposite handedness. Outwards movement prior to rotating can be achieved using linear actuators known to the art. If the motion of the cups away from one another occurs prior to the motion that moves the cups toward the clamps, the cups can achieve frictional traction on the flap while the flaps are pressed between opposing cups to provide a normal force and/or by using some level of vacuum. Once the opposing cups have separated, vacuum can provide the necessary traction to flatten the flap.
The dispenser may comprise one or more blades 83 over which the films comprising the walls of the pouch are bent and redirected while the pouch is peeled. The blades 83 in the 3D view of
Peeling/unsealing of a pouch that has not previously been opened is an active process that requires the application of forces to directly and controllably separate the films that are sealed together (in some embodiments the forces can be reduced significantly such as by pre-weakening the seals (e.g., using a light-degradable adhesive similar to that used in wafer dicing tapes in the semiconductor industry)). While useful in some cases (with flowable ingredients), it is in many cases undesirable to achieve opening by merely applying pressure to the pouch, since this can result in rapid, uncontrolled ejection of the pouch contents. Prior to unsealing it for the first time. the pouch should be fully sealed to prevent premature release of its contents or exposure to the environment.
At the time shown in
Once the clamps have moved to their highest desired position for a given pouch (whose height may vary), the pouch walls have been fully peeled. In some embodiments the upper seal of the pouch is peelable, while in others it is non-peelable. Moreover, at some point the pouch cannot be further peeled because of the grippers grasping it at its top. If there is some head space in the pouch above the food item, then at the end of the upward stroke of the clamps the film forming the head space may be between the blades. To allow the maximum amount of peeling, the grippers may be lowered more than usual just before peeling ends to increase angle 144.
Once peeling has ended, the motion of clamps and grippers may be reversed, such that the peeled, empty pouch is pulled upwards through the dispenser. Once the clamps have reached their lowest position (or sooner), the lower clamp separates from the upper, releasing the flap and allowing the pouch to be removed and disposed of. The position of the cups may be reset to prepare for the next pouch.
In some embodiments to supplement the action of the blades in removing adherent portions of food from the inside walls of the pouch, other methods and apparatus may be used. For example, using an actuator to vibrate or tap the film (preferably contacting its clean outer wall) between the pouch and blade or downstream of the blade, or vibrating the blade, can be useful. Passing the film (e.g., between pouch and blade) over a surface having ripples 176 such as that shown in the 3-D view of
As shown in
In some embodiments a dispenser with curved tracks can be used with pouches having full-width flaps if the flaps can be slightly separated enough to allow clamps similar to those described above—or clamps which are much narrower and which slide in horizontally—to grasp the flaps from both sides.
Pouches that are peelable or otherwise allow their walls to be mostly separated allow for the most flexibility in dispensing and therefore can accommodate the greatest variety of food items; however, pouches containing Type 1 or 2A items need only be able to be opened at their bottoms. Universal dispensers which can handle Type 1, 2A, and 2B items are described above; however, in a machine handling a limited number of items, or using multiple dispensers (using different ones to handle different item types) this may not be required. A dispenser for a Type 1 item only packaged in a pouch with a burstable seal might involve only a squeezer such as that of
Depending therefore on the type of food item and type of pouch, dispensers may therefore include any combination of means for grasping flaps (e.g., vacuum cups), means for pulling flaps apart (e.g., peelers), means for squeezing the pouch (e.g., squeezers using squeegees or bladders), and means for bending and redirecting the film (e.g., blades). In some embodiments elements may serve more than a single role simultaneously.
Once in the dispenser the flaps are grasped (box 1516) and if not already done, the controller determines (box 1518) the approach to dispensing it will use, based on the food item type (1, 2A, or 2B). Per box 1520, if the item is not Type 1, then it is necessary to determine if it Type 2A or 2B in box 1522. In box 1524, if the item is not Type 2B (thus, type 2A), the pouch is opened at its bottom seal (either fully all at once, or partly/gradually, to control the outwards flow) to discharge the item, and time is allowed (box 1526) for the item to come out. If the item is of Type 2A, then the pouch is peeled fully open (box 1528) by the dispenser while the gripper moves to support the pouch and provide tension in the film. With peeling completed, the peeling motion is reversed (box 1530). Per box 1520, if the item is Type 1, then based on parameters of the specific ingredient (e.g., viscosity), the controller determines (box 1532) whether to peel open the pouch to its full width (and if so, how quickly) or just partially (e.g., forming a narrow funnel by partially peeling a chevron or diagonal bottom seal). If it is to be opened fully (box 1534), this is done by the peeler, and a speed is set for squeezing, also based on parameters of the specific ingredient (e.g., if very viscous such as peanut butter, a lower speed may be required to avoid stalling the actuator). If the pouch is to be partially opened (box 1536), this is also done by the peeler, and a speed also set for squeezing; this speed may be set lower than that used when the pouch is fully open, since the opening is narrower and flow cannot be as rapid (if too squeezing is attempted, pressure of the item inside may itself further open the pouch). In box 1538, the squeezer is activated, in box 1540, time is allowed for the ingredient to completely fall out, and in box 1542, the squeezer is reset to prepare for the next pouch. Lastly, regardless of pouch type, the flaps are released (box 1544) and the pouch is extracted from the dispenser and disposed of (box 1546). In some embodiments, rather than merely waiting a certain time for items to fall out of the pouch, the weight of the pouch or that of the receptacle into which the item is falling, can be monitored, and when the weight gain reaches a threshold indicating the pouch is empty or nearly so, the process is allowed to continue. In some embodiments the pouch is accelerated or jerked upwards, vibrated, shaken, etc. just before the pouch is withdrawn from the dispenser and while the receptacle is still in place. This can loosen any food item drops or particles still clinging to the pouch and reduce the risk of it dripping or falling during withdrawal and contaminating the system.
Though an ingredient may be categorized of Type 1 or 2A, it may not adequately dispense if so handled, e.g., due to variations in the specific food item, temperature, humidity, etc. Thus, weight loss of the pouch, weight gain of the receptacle, or motion of ingredients leaving the pouch can be sensed, and if the evidence suggests ingredients remain within, then full peeling can be implemented according to the (slightly more time-consuming) 2B approach.
Individual Pouch Storage
Individual pouches—as opposed to pouch chains—can be stored for use in an automated food preparation system in a number of ways.
A pouch such as that of
The stops are designed to be wide enough to prevent the pouch from travelling too far, but narrow enough to allow the pouch to deform so it can be pulled out of the cubby through gaps 269 (and the center region of the cubby which is free of ramps) by graspers or similar means introduced at the front of the cubby (
In some embodiments cubbies such as those in
As shown in
In some embodiments cubbies such as those in
In some embodiment variations, gates/barriers/stops may be provided within the cubby which prevent pouches behind the “lead pouch” (that nearest the front cutout (
If the cubby support (i.e., floor) 286 is covered with a high friction material (e.g., rubber, 3M Gripping Material) such that pouches cannot normally slide even though the support is tilted, then vibrating the support (e.g., with inexpensive cell phone-type vibration motors) or the entire cubby may be used to control feeding of pouches toward the stop. For example, if the support is subdivided into separate sections (e.g., there are three supports, one for each pouch in a three-pouch cubby) and if each support is provided with its own vibration source, then by controlling these individually, each pouch may be fed to a desired resting location with the cubby without disturbing other pouches. A sequence for loading and unloading a tandem cubby using this principal is shown in the cross-sectional elevation views of
In
Approaches such as those in
Other methods of loading multiple pouches into a cubby and fetching the pouches are used in some embodiments. For example, the cubby support 311 may be covered with a conveyor belt 312 running over outer pulley 313 and inner pulley 316 which is optionally provided with regularly-spaced flights 314 as in the cross-section elevation view of
In some embodiments, rather than provide multiple actuators or use passive movement of a belt, the belt is designed to not move on its own, and the grasper—used to remove pouches from the cubby and bring them to the dispenser—may also be used to advance pouches within the cubbies. For example, in the cross-sectional elevation view of
In some embodiments pouches located within a single tandem cubby can be accessed regardless of their position by arranging for the grasper to reach far into the cubby. The grasper body may be made long enough and/or openings may be provided in the cubby to allow access of the grasper as well as its support structure.
In some embodiments the grasper is able to load pouches into cubbies when so commanded by the machine controller, not only remove them. This capability allows pouches (e.g., multi-compartment pouches) whose ingredient has only been partly dispensed, to be replaced in a cubby. It also allows the machine to load pouches that are supplied to it in a different format than already within a cubby (e.g., within a box) to arrange pouches in cubbies for easy and rapid access, and to re-arrange pouches within cubbies by removing them from some cubbies and replacing them in other cubbies. If pouches are stored more or less vertically (similar to the those in the drawer storage unit of
If pouches are loaded into cubbies by a technician, the bar code, RFID, or other identifying, machine-readable code on it can be scanned by passing the pouch before a scanner before loading it into a cubby. The entrance to the cubby can be provided with a sensor (e.g., photoelectric) so that the controller knows in which cubby the just-scanned pouch is placed. If cubbies are loaded by the machine itself (e.g., from a box left inside the machine by a technician making a restocking visit), then pouches can be scanned (e.g., passing them before a fixed scanner) just before placing them into cubbies, and since the controller knows which cubby receives which pouch, the sensor may not be needed. In some embodiments, pouches are loaded into cubbies randomly, and then scanned to identify which ingredients are where, as well as pouch parameters such as expiration date; a scanner for that purpose may be incorporated into the grasper or associated hardware, or may be more remote if it has a longer working distance (e.g., a long-range barcode reader).
In some embodiments, shelves may comprise cubbies, while in other embodiments, shelves may comprise modules which comprise cubbies. In the latter embodiments, modules serve as smaller shelving units which can be a) combined to form larger shelves; b) can be individually removed and replaced in the machine; c) can mutually interlock to facilitate transporting several modules at once. Modules or shelves may also be insulated, and may include doors (e.g., rollup or accordion-style) to prevent possible loss of pouches during transportation and maintain internal temperatures better. Shelves or modules can be collapsible (e.g., accordion-style) or be rigid, and can be reusable or single-use.
In some embodiments, cubbies, modules, or entire shelves may be able to tilt temporarily for loading so that when loading a pouch from the “front” (i.e., exit end) of a pouch, the cubby is oriented with the cubby exit is the highest region of the cubby, rather than the lowest region as usual. In some embodiments, the pouch may be swung while hanging from the grasper as in
The belt is supported and moved (e.g., bidirectionally per arrows 341 as shown) by pulleys 342 at the top and bottom. A machine using such a storage system can include at least one storage system such as that of
When a pouch box is at the top of the belt, pouches 344 inside can be accessed by using a grasper 346 to grasp the top seal area of the pouch and then withdraw it in direction 348. While the grasper may need to move in and out of the plane of the figure to access different pouches in a box, it need not move over a large vertical distance.
In some embodiments pouch boxes are not attached to a belt, but are simply stacked vertically (e.g., along one or more sides of the machine). In such a case, boxes are actuated to individually slide outwards (e.g., one at a time) and back so that their contents can be accessed, somewhat like a file drawer can open and close.
In some embodiments pouches are placed in pouches with their top seals 356 down, and are withdrawn from the bottom of the box by grasper 346 held by support 358. The grasper can flip them over so their flaps are at the bottom before introducing them into the dispenser. Or, the pouch can be allowed to fall onto a specially-shaped chute or other surface that catches them momentarily, allowing them to be grasped, or causes them to tilt and at least partially invert, facilitating grasping of the top seal, etc. In some embodiments clips retaining pouches are released by a mechanism near the dispenser.
Machines having multiple dispensers (e.g., each with a different ingredient) may be configured similarly to those of
In some embodiments machines may store ingredients in highly-insulated chambers (e.g., vacuum or aerogel-insulated) to reduce the power consumption required for operation, and allow ingredients to remain edible even after a power failure of reasonable length. Such machines may incorporate a “cold” fetching system that works entirely within the chamber, and which brings pouches to an external pouch transport system which can bring the pouch to the dispenser and possibly participate in dispensing its contents. Pouches may pass through a single opening in the chamber that is normally kept closed, and which may incorporate a double door.
Second System
A system intended to serve multiple customers, using shelves and a single dispenser such as that of
Below the dispenser is dish 372, which can be moved by a dish transport 374 allowing the dish to be located under the dispenser in one or more positions and/or orientations such as toward the front of the system (e.g., if empty dishes are manually inserted by the customer, or for delivery to the customer of a meal), etc. In some embodiments the transport may provide two or more axes of motion, such as both X and Y (per the coordinate system on
In the embodiment shown, pouches 378 are transported by a manipulator comprising graspers 380 having grippers (e.g., pneumatic) fixed to a rotary actuator 381 similar to 280 supported by arm 382 which is moved along the X, Y, and Z axes by X (384), Y (386), and Z (388) linear stages, respectively. In other embodiments, other stages, including those with rotary joints may be used. The rotary actuator allows pouches to be fetched either from (or in some embodiments returned to) shelves on left or the right side of the system, and allows the pouch to be re-oriented vertically (e.g.,
In
In some embodiments the rotary actuator or grippers may incorporate at least one paddle which can support the pouch from underneath when it is not vertical, e.g., when it is in the position shown in
The manipulator may also fetch and move pouches where are not inserted into the dispenser, but rather, placed into a chute or delivery compartment directly. Such pouches include ingredients which the customer requests to be “on the side” such as a sauce or a salad dressing, pouches which are close to expiration which are to be given to charity unopened, etc. The system can also dispense unpackaged items (e.g., fruit such as bananas) if they can be grasped, cutlery and napkins (e.g., packaged in a pouch), beverages (e.g., Capri Sun, Kraft Foods) in pouches, or snacks in pouches (e.g., trail mix, chocolates). In some embodiments the manipulator can dispense items in other than in flexible packages, such as in bottles. Grocery items, ready-to-eat meals/snacks, and packaged components of meal kits (e.g., to be used for home cooking) are among the items that can be provided to a customer.
In some embodiments the system may incorporate at least one additional manipulator, e.g., a secondary manipulator (e.g., one able to move in Y and Z) which can take over some of the functions of the dispenser described. For example, the primary manipulator may fetch pouches from a cubby and deliver them to the MEP or heater, while the secondary manipulator may remove them from the MEP or heater, bring them to the dispenser, participate in dispensing their contents, and move them to the waste bin. If the work envelopes of multiple manipulators overlaps, the system controller, knowing (e.g., through sensor feedback) the position of all elements of each manipulator, can issue commands that avoid any collisions.
In some embodiments systems similar to that of
Pouch Grasping and Fetching
Grasping the top of the pouch repeatably and symmetrically (e.g., grasper centered on the pouch, pouch inserted into grasper the same distance everywhere) from a cubby like that of
Due to possible distortion of the pouch caused by the weight of the ingredient inside, or packing the ingredient under vacuum or excess pressure, the top edge of the pouch may not be very flat, making uniform grasping more difficult. To remedy this, the grasper in some embodiments comprises at least two separate pairs of jaws spaced apart and moveable relative to one another. With such a design, once the edge is grasped, the pairs can be moved apart in a way that applies tension to the top seal of the pouch to flatten it, if necessary.
In some embodiments, to speed up the process of food preparation, or provide better thermal insulation between cold and warmer areas of the machine, at least two separate robotic grasping/pouch transport systems may be used in the same machine, the first of which removes the pouch from storage and the second of which brings the pouch to the dispenser and optionally, participates in dispensing the ingredient. While the second system is doing this, the first system is free to fetch the next pouch, or the first system can return an incompletely dispensed pouch to storage while the second system brings a pouch from the MEP to the dispenser, etc. In some embodiments the first system may place a pouch in an MEP, pouch heater, etc., from which the second system then picks it up. In other embodiments, one system may directly hand off the pouch to the other.
Pouch Variations
In some embodiments pouches may be used having specialized features. For example, the pouches shown in the 3D views of
The pouch of
Controlled Dispensing
In the above figures, pieces exit the pouch even though the walls are still joined together (though external vacuum cups may be used to help separate them), or air may be introduced into the pouch to expand it, etc.
In some embodiments, rather than individually dispense pieces of an ingredient as in
Dispensers, Dispensing, and Pouch Manufacturing
Complete or nearly-complete dispensing of ingredients from pouches as described herein is not merely more efficient and less wasteful. It also reduces the risk of machine contamination by residual ingredients, reduces the potential for food spoilage odors, and reduces the risk of attracting insects and vermin.
Methods and apparatus disclosed herein can minimize or eliminate direct contact between machine and ingredients, with ingredients only contacting disposable/consumable materials, or those which can be easily removed for cleaning. Direct contact can easily contaminate the machine, cross-contaminate other ingredients, and necessitate regular and thorough machine cleaning (which can make unattended operation difficult if not impossible). Avoiding direct contact in a home appliance saves time and effort in cooking. In a public/vending-type machine, it reduces the need for service visits, greatly improves food safety, and eliminates the need for rinse liquids and waste disposal (e.g., water and drain plumbing), thus allowing the machine to be installed temporarily or permanently in a much larger variety of locations/venues.
Referring to dispensers such as those shown in
With reference to
The dispenser can be subdivided into multiple subsystems.
The spreader of
Substantially symmetric, simultaneous rotation of the two arms can be produced by various mechanisms including independent motors, motors with gearing, and the mechanism shown in
Due to the weight and volume of the ingredient within the pouch and/or due to outside air pressure (if the pouch is vacuum packed) or due to the pressure of an internal gas (e.g., if packed with air or a modified atmosphere), the pouch may be distorted such that the flaps are no longer substantially planar as in
In operation, both air slides (in some embodiments only one may be used) are initially positioned inwards. Once the grasper (not shown), whose jaws hold the pouch by its upper portion, has lowered the pouch to a height suitable for dispensing (e.g., the height at which the finger extensions are approximately aligned with the apex 522) as in
Turning now to
Before peeling can be initiated, a gap is required between the lower and upper clamping surfaces as shown in
The inward edge of the squeegee may be tipped by a material (e.g., PTFE) that has preferably low friction when sliding on the pouch walls or guider film, and may be somewhat compliant. The tip 562 may be sandwiched between the squeegee and a tip support 564 or just held in place with fasteners, adhesive, etc. In some embodiments, the tip may be replaced by one or more rollers (e.g., passively rotating). When the squeegees of both squeezers are extended, the gap between the tips may be small (e.g., no larger than the thickness of the films comprising the pouch and guider films, thus forcing the pouch contents in regions impinged by the squeegees to be expelled substantially completely.
The squeezer also comprises a frame 566 to which the squeegee is mounted through pivot 555, and which moves the squeegee downwards along the pouch when the frame is driven along two guide rods 568 by two lead screws 570, the latter turning within lead nuts 572 attached to the frame. The screws, equipped with pulleys, are rotated by a motor 574 turning pulley 577 which moves belt 576 running over idler pulleys 578 as in
An optional guider 580 can be seen in
In some embodiments, the entire guider may be easily detached for the dispenser and removed (e.g., for cleaning after contamination by a ruptured pouch or by an ingredient falling from the open end of a pouch from which most of the ingredient has been already dispensed if the pouch is lifted out of the dispenser for disposal, etc.). In some embodiments, the guider film may extend further, so as to wrap around the blades and protect them from contamination as well. In some embodiments, the guider film may be provided in an extended shape (e.g., a web stored on a spool and taken up by another spool), a continuous loop, etc.). In such cases, damaged, worn, or contaminated sections of the film can be automatically moved out of position (with new/clean sections replacing them) and collected for disposal/recycling, or cleaned automatically within the system.
Before the start of the process, the grasper grasps the pouch and brings it to position at the entrance to the dispenser (e.g., between the guider films). Once the process starts, the dispenser is initialized (box 590) to move all actuators to their required initial states if not there already. For example: the spreader arms may be separated, creating a gap between the pads; the grippers of the tensioner may open to allow the pouch to enter the space between the finger extensions; the air slide tables may move the grippers inwards in preparation for moving outwards to tension the pouch once it is securely gripped; the peeler may be lowered so that the lower clamp is at its lowest position and the upper clamp rests on the support rod, creating a gap between the two clamps; and the squeezer may be raised to position the squeegee to squeezer out the contents of the pouch (for a Type 1 ingredient) and/or to not interfere with the peeler if the latter must travel a long distance upwards (for a Type 2B ingredient). Next, the pouch is lowered into the dispenser (box 592). Once the pouch has reached the correct height (e.g., aligning the apex of the chevron with the gripping portions of the finger extension (see
If vacuum is used to assist pulling on the flaps, it may be delivered to the pads (box 598) if not already applied. Next, the arms are separated (box 600), moving the pads further from one another, and pulling the flaps apart and into a new orientation. When the flaps have entered the peeler (e.g., entered the space between lower and upper clamps), the lower clamps of the peeler are raised (box 602) until the flaps are sandwiched between the lower and upper clamps and thus are securely grasped. If vacuum has been used, it may now be turned off (box 604). To help separate the flaps from the pads to which they may tend to adhere, compressed air may be delivered to the pads at this time; once the flaps are separated, this can be turned off. Before moving the peeler to peel open the pouch (and in the case of Type 2B ingredients, continue to peel it, e.g., until most or all of the peelable seal is separated), the grippers, if used, may be opened (box 606). Then, the peeler lower clamps are raised; this also raises the upper clamps since the lower clamps push them upwards box 608). To avoid slippage of the flaps in the peeler or of the pouch in the grasper, or rupture of the pouch, and to maintain a desirable tension in the pouch films (especially as they pass around the blades for Type 2B ingredients) as the peeler rises, the grasper must descend. The relative speeds of movement of these can be determined geometrically and implemented open loop, or in some embodiments a sensor (e.g., a switch in contact with the film, preferably on its clean, outer surface) may be used to sense tension in the pouch and adjust the relative speeds accordingly. By incorporating some compliance in the grasper/pouch/blade/peeler system (e.g., mounting the blades compliantly, such as using leaf springs), controlled tension may be more easily achieved. Once the peeler is sufficiently raised, the pouch will be peeled open at the apex of the chevron. Opening the pouch is of course required for all types of ingredients.
If the ingredient is determined (box 610, e.g., by consulting a local or remote database with the code on the pouch) to be of Type 1 (e.g., flowable), it can be dispensed by use of the squeezer. Before this, it may be required to further open the pouch (box 612). The amount by which the pouch is peeled open (i.e., how much of the chevron is peeled: the region near the apex, the entire chevron to full width of the ingredient compartment, or an amount in-between) before using the squeezer depends on several factors. These include the ingredient viscosity, the desired width of the flowing ingredient as it issues from the pouch, and the desired flow rate. The squeezer speed (whether variable or fixed) may be adjusted according to factors such as ingredient viscosity, the desired size of the opening (if less than the full width), and the peel strength of the seal, and should not be exceeded since that may increase the pressure within the ingredient compartment of the pouch and potentially widen the opening or cause seal/pouch rupture. Before extending the squeezer's squeegees, the squeezer may be lowered to a suitable position (e.g., below the graspers) (box 614). Once in position, the squeegees can be extended (box 616) and lowered (box 618) until as much of the ingredient as desired has been dispensed. Some time may be required (box 620) for the ingredient to be discharged before the pouch is extracted from the dispenser, after which the squeegees may be retracted (box 622). In some embodiments to facilitate complete dispensing of the ingredient, the grasper may be raised, pulling the pouch upward through the squeegees: this may require that the pouch flaps are released or the peeler is lowered.
If the ingredient is not of Type 1, it may be of Type 2B (box 624). If so, then the peeler continues to rise while the grasper continues to descend (box 626) as already described. The motion of these is then reversed (box 628) beginning the process of removing the pouch from the dispenser, and also giving the ingredient more time (box 625) to fall off the pouch inner surfaces (e.g., while the surfaces pass around the edges of the blades). If the ingredient is of Type 2A, a delay may be provided for it to fall out of the pouch.
Regardless of the ingredient type, if the pouch flaps have not been already released, they may be released (box 630) and the pouch then extracted (box 632) from the dispenser once the dispensing process is completed. The pouch can then be transferred to a waste container.
As shown, in some embodiments, the films may be misaligned (i.e., partially but not fully overlapped) such that when combined, the width of the pouch exceeds the width 641 of one film, and vertical regions 643 on either side of the peelable seal comprise only Film 1 or Film 2, since in such regions there is no overlap of the films. Having portions of the flap not overlap facilitates access of the arms to the flaps, and allows flaps to be pushed in regions 660 and 662 (optionally while being clamped between two bodies)—not just pulled—to separate and reorient them in preparation for clamping by the peeler. Pushing/clamping can be more reliable and repeatable than pulling, can allow for greater force (and reduce the need for pouch tensioning), and can avoid the possible need for tacky materials (which may become contaminated with dust, etc. or otherwise become less tacky), vacuum pumps, etc. Pouches such as that of
Separation and reorientation of such flaps can be achieved in some embodiments as shown in the elevation views of a pouch (at a right angle to those of
In
The passive clamp is able to move when moved by the active clamp, but in the embodiment shown, is prevented (e.g., by a stop, not shown) from moving counterclockwise past a certain angle (e.g., that shown in
In
In some embodiments in lieu of using a pouch formed from misaligned films, a pouch formed from perforated (e.g., pre-perforated) films may be used such as those shown in
The pouch design of
For clarity,
In
In some embodiments pins similar to those of
The mechanism in the embodiment shown comprises mount 720 which can attach to the dispenser or a nearby structure; stepper or servo motor 722; bracket 724 to mount the mount onto carriage 726 that can translate a short distance along rail 728 (other methods of allowing the motor to translate may be used, such as flexures); lead screw 730 (preferably with multiple starts); lead nut 732; a clamp (not shown) holding the lead nut to the mount; coupler 734 to join motor shaft 735 to the screw; two arms (736 fixed to the screw and rotated by the motor, and 738 passive) each ending in a pad 740 (preferably having a non-slip surface), standard and thrust bearings used inside and on the sides of the passive arm; at least two springs; a collar 752 which retains the arms, bearings, and springs on the screw, and an actuator (here a small air cylinder).
In operation, passive arm 738 is initially held in a raised position (
In
Referring to
In some embodiments pouches with notches in their corners may be unsealed by apparatus similar to that of
The method is essentially that depicted in
In
The wheel rotation required can in some embodiments be produced by having the wheel turn eccentrically on shaft 792 (e.g., equipped with a torsional spring to return it to its original position) as shown in
For ingredients which adhere to the inner surfaces of the pouch films, pulling on the films to peel them (especially for a Type 2B ingredient) in which much or all of the pouch is peeled open), the moving pouch films can serve as a “conveyor belt” transporting the adherent ingredients toward the blades, where they often detach and fall into a dish or other substrate below as in
Vibrating, shaking, or tapping the film before and after it passes around the blade can be helpful to dislodge adherent ingredients. In some embodiments, this is done directly to the film, while in others, it can be done to elements of the machine in contact with the film, such as the blade. For example, the blade, which may be compliantly mounted, can be struck by one or more oscillating rods (e.g., from a small solenoid or air cylinder, e.g., impinging on its top surface), or may have mounted to it one or more small vibration motors.
The ability to translate the dispenser with respect to the dish or vessel into which an ingredient is dispensed, or vice-versa, along two axes allows for a given ingredient to be placed within the dish at a specific location. This can be achieved, for example, using two linear motions, or one linear and one rotational motion. In the case of some ingredients—especially those that are not roughly equiaxed (e.g., baby carrots, rolled cookies) or symmetric, it can be beneficial at least aesthetically to provide an additional motion axis, allowing the ingredient orientation to also be controlled.
Pouch flaps generally become curved and distorted, and difficult to flatten and rotate to a position that allows them to be grasped (if they need to be separated in order to grasp them) due to the distortion of the pouch caused by the weight and volume of its contents, or due to the evacuation of air inside the pouch, or pressurizing the pouch with a modified atmosphere gas, as the case may be. In the case of a Type 1 ingredient, the effect of gravity can exacerbate the distortion when the pouch is oriented normally (flaps at the bottom). Thus, in some embodiments, to facilitate flattening of the pouch flaps so as to make the flaps easier to rotate, the pouch can be tilted to another orientation (e.g., horizontal, partially or fully inverted) before the flaps are rotated. Once the flaps are grasped securely, the pouch can be reoriented as needed for dispensing.
If a pouch is vacuum packed or contains air or a modified atmosphere gas, then before the pouch is opened (e.g., before attempting to re-orient the flaps before they are gripped by the peeler clamps), the pouch can be opened (e.g., near the top) in a small area to allow gas exchange and minimize pouch distortion caused by the pressure differential between inside and outside the pouch. This can be done by piercing or ablating the pouch, peeling it in a particular region (e.g., a pull tab may be provided for this that the apparatus can grasp and pull), tearing or cutting it (e.g., a tear notch may be provided, etc.). If a permanent part of the machine comes into contact with the pouch, it preferably does not come into contact with the ingredient within the pouch. To avoid this in some embodiments a gas-permeable but otherwise impermeable material (e.g., TYVEK® or GORE-TEX®) may be incorporated into the pouch adjacent to the location where the pouch is opened.
For Type 1 ingredients, after opening the pouch and before extending the squeegees, the pouch can be raised (while simultaneously lowering the peeler clamps) so that the squeegees can travel over more of the full height of the pouch; without this, the lower portion of the pouch may be too low for the squeegees to reach, such that some of the ingredient remains in this region.
In some embodiments it is desirable to have the opening of the pouch as close as possible to the dish or vessel below it (e.g., to reduce the risk of splatter as the ingredient falls). This can be accomplished by lowering the pouch relative to the blades, thus making the pouch films between the blades more horizontal. Increasing the angle between the two films between the blades can also reduce the tendency of the ingredient to cling to the inside surface of the pouch as it issues from the opening.
Some ingredients within a pouch may tend to clump together. To separate them for use, several methods can be used, depending on the ingredient. For example, air may be let into the pouch if previously under vacuum, and the pouch may be inflated to increase its volume, after which the pouch can be sealed or held closed, and agitated (e.g., tumbled) to help break apart clumps. Without contacting the ingredients, the pouch can be vibrated, shaken, folded, twisted, rolled, etc., or one or more blunt tools (e.g., interleaved) can impinge on the pouch walls (e.g., rolling, pushing) to help break up clumps inside. Liquid (e.g., water) can be introduced into the pouch, which can tend to separate clumps held together by surface tension; the liquid can then be drained before dispensing the ingredient. To avoid ingredient clumping, separator sheets, tubes, or other shapes within the pouch can be included, made from parchment paper, wax paper, etc. These can be fixed to the pouch (e.g., at the top and/or sides) so that they don't fall into the dish when the pouch is opened.
In some embodiments pouches, especially those containing Type 2B ingredients, can be everted (turned inside out) to dispense the ingredient within. This can be especially useful for pouches that are reusable and flexible (e.g., elastomer pouches used in a home appliance such as that in FIGS. 31(a)-(l) of the 074 and 253 filings.
In dispensers such as that shown in
The pouch guides of
The grasper of
When loading a pouch into a dispenser, to avoid inadvertently folding the flap the system can a) move the pouch past the dispenser center when moving horizontally, then center it; b) move the pouch vertically below the height at which dispensing will begin, then raise it to that height. Bristles or similar biased structures which preferentially allow motion in one direction (e.g., downwards) but not upwards can be useful to unfold the flap during these movements or otherwise.
If the rate of an ingredient being released from the pouch isn't well controlled, the motion of the dish below it can be coordinated with it nonetheless by sensing the actual rate and adjusting the bowl motion accordingly. For example, if the dish is weighed during dispensing, and/or if the pouch is weighed, rates can be determined. Sensing may also be used, such as optical sensing to measure such behavior as an ingredient protruding from the pouch, detaching from the pouch, pouring out of the pouch with a particular stream diameter, etc.
Pouches holding some ingredients (e.g., Type 1 or 2A) can be opened by means other than peeling, and therefore may not include flaps. Such means are preferably non-contact, to avoid any contamination of the system (thus cutting them open with a blade, unless disposable or easily and thoroughly cleaned, is undesirable). For example, pouches can be opened by using a laser (e.g., carbon dioxide, excimer, diode) to burn, melt, or ablate the pouch material along a path that opens the pouch. Similarly, plasma, electrical discharge, and other methods may be used, depending on the pouch material (e.g., polymer, metal) in the region of the pouch to be opened.
In some embodiments, pouches without flaps containing some ingredients (e.g., Type 1 or 2A) but having at least one peelable seal may be used. These may be peeled open by grasping the sides of the pouch (e.g., using vacuum) and pulling them apart, by pulling on a portion of the pouch to tear it (e.g., using a tear notch to start the tear, and optionally using pre-scoring the pouch to guide the tear, or pulling on an embedded string or wire.
Systems
Systems such as that of
In Box 828 of
Referring now to
Certain steps in the flowcharts may in some embodiments not be in the strict chronological order shown or described herein, but may occur in a different order or simultaneously.
Some automated food preparation systems may include fire detection and suppression systems, as required for safety. Some systems may generate fumes and/or grease vapor/gas/particles or smoke and may include an exhaust duct or other filtration system that can be cleaned or replaced. In some embodiments the system may include at least one chambers which is refrigerated (e.g., for ingredient storage) and at least one other chamber in which heating of ingredients takes place. In addition to thermal insulation between such cold and hot chambers, double doors or airlocks may be used to transfer pouches and/or dishes and vessels from one chamber to another, to minimize heat transfer between them.
Some automated food preparation systems may be used on a vehicle, such as an airplane, bus, or train. Such systems may also include delivery to passengers. For example, a system may dispense (and possibly further process, such as heat) ingredients into a dish, add a lid (snap-on, heat sealed film, etc.), then move the dish to the passenger via an overheat conveyor/trolley (having sensors to avoid collisions). With such a system it becomes possible to eliminate the standard approach to serving meals on a plane, for example, which requires a cart pushed by flight attendants (who may have other responsibilities, or in case of turbulence, should be belted into a seat), resulting in fresher/better meals and snacks.
Since pouches are small and lightweight, then a food preparation system can be very mobile: collecting from a fixed (or larger mobile) storage system only the pouches needed for a particular dish or dishes, and transporting these to the customer, preparing the food while en route or upon arrival to maximize freshness. Thus, systems can be built which provide food to a hotel, hospital, or dormitory room; apartment or condominium; or which using small robots (e.g., autonomous) and other platforms to bring food to passengers of a car (parked or moving) by rolling, flying, or (if the passengers are in a boat), optionally navigating on water. In some embodiments (e.g., for delivery to a moving vehicle) a docking station may be provided on the vehicle so that the delivery/food preparation platform can temporarily dock with the vehicle while transferring food to it. For example, delivery of fresh food to a car, truck, or bus that is moving toward a destination is achievable.
In some embodiments machines may incorporate peristaltic pumps to transport flowable ingredients, with the pump tubing replaced when needed (e.g., potentially very infrequently if pumping water).
In some embodiments multiple squeegees/rollers may be used in a dispenser on each side of the pouch, such that the contents are pushed out by more than one, acting in succession, or with each squeegee/roller travelling over only a portion of the pouch compartment height.
In some embodiments one or more paddle wheel-like devices exterior to pouch 885 (so they are not contaminated) with flaps 893 and containing ingredient 891 can be used to control dispensing of ingredients from the pouch (e.g., those which might ordinarily fall out too quickly).
Minimizing Cleaning
In some embodiments mixing, blending (e.g., to prepare a smoothie), and similar operations on ingredients may be performed such that no cleaning of the machine is required, since no non-disposable/non-consumable portion of the machine comes into contact with any ingredient. For example, an immersion-type blender with blades, a shaft driving the blades, and a motor at the top turning the shaft, may be lowered into a disposable cup used for serving the smoothie. The blades and shaft of the blender may be covered with a disposable coating material such as a plastic film, which can be automatically inserted and removed by the machine. Alternatively, the blades—and in some embodiments, the shaft—can be disposable.
A knife (e.g., an ultrasonic knife, which might be used for cutting sandwiches) can be covered (e.g., wrapped at least partially under tension, held by vacuum or temporary adhesive) with a disposable film (e.g., foil, hard plastic like PET) so it can cut food items without contamination and need for cleaning. If cleaning or an ultrasonic knife is needed, it can be made more effective by applying/immersing it in a cleaning fluid (e.g., water) to the knife while ultrasonically vibrating it. Slicing and chopping of ingredients within a pouch can be achieved using pressure and/or ultrasonic energy applied through the pouch walls. Ingredients can be separated (e.g., torn, broken) within a pouch by clamping two portions of the pouch and pulling them apart, twisting, bending, etc.
Systems having surfaces that do come into contact with ingredients can be sterilized by a number of methods such as hot air, hot water, sterilizing liquid (e.g., heated), steam, ultraviolet light, e-beam or other radiation, etc.
Pouch Filling
In some embodiments a “mold” may be provided for pouches which clamps the pouch along its peelable seals (sides, chevron) but bends or deforms to allow the pouch to expand and open for loading (vacuum may be used to help the pouch open/stay open). The mold allows ingredients to be forcefully “stuffed” into the pouch without the risk of peeling/damaging the seals. In some embodiments grippers which grasp the pouch while in a pre-made pouch filling/sealing machine can also prevent peeling; such grippers can be larger than usual to protect more of the seal, including the chevron. Such grippers can also shake the pouch to encourage settling of an ingredient loaded therein, allowing more to be added and ensuring the top seal region of the pouch is free of the ingredient.
Pouches can be filled with ingredients in some embodiments by 1) pulling apart their opposite walls (e.g., using tacky pads and/or suction cups provided with vacuum) at least partially; 2) inserting a curved liner/expander (
The top seal of a pouch may be created using a variety of sealing methods including heated (impulse or constant heat) or ultrasonic sealers. If using a band sealer, pouches can be fed into the moving band using feed rollers or belts whose tangential speed is lower than that of the band sealer, and with provision for the pouch to slip within the rollers/belts (or their drive can be made to slip using a clutch), thus providing tension across the top seal area prior to sealing, to ensure the seal is formed correctly and without wrinkling or other potential sources of leakage.
Pouches in a continuous chain (
A group of pouches to be filled may be supported (e.g., in an “eggcrate”-like structure lying horizontally, or a pouch box, or a shelving unit or module thereof (e.g., a module with rotatable cubbies with the open ends of the cubbies pointing upwards), and filled one by one (or with at least some pouches filled simultaneously) and then sealed. To remove air from pouches before the seal area is compressed and then sealed, a vacuum snorkel can be used (which can move along with the pouches if using a band sealer), or the pouch can be mostly immersed in a container filled with liquid (e.g., water) which moves along with the pouch on the sealer's conveyor belt, or has the form of a long trough through which the pouch moves. In lieu of liquid, a fluid-filled flexible bladder or bag, e.g., moving along the belt, may be provided to surround the pouch and squeeze out air.
Ingredient Heating and Cooking
To eliminate or at least minimize contact between ingredients and the system that assembles/processes them before serving a meal or snack (thus minimizing microbial growth, the need for cleaning, and inter-contamination), it is desirable to perform various heating (or cooling, as the case may be) and cooking operations within an ingredient package (e.g., pouch). The package can be one that contains at least one of the ingredients, or one specifically used for heating/cooking and into which ingredients are transferred. Or, surfaces of the system can be made easily cleanable or covered with replaceable (e.g., single-use) materials that prevent direct contact with ingredients.
The 3D view of
In some embodiments, no supports are needed. Once a pouch containing an ingredient is sufficiently opened and pulled away from the ingredient, the ingredient can be retained (e.g. in a vertical orientation) near its top, and exposed to a heat source. For example, a slice of bread may be toasted by peeling the pouch while lowering it vertically until the bottom of the slice rests on a dish or other substrate. The top of the slice can be stabilized by the pouch films or the dispenser squeegees (which may be extended to clamp the slice near its upper surface if needed). Once the bread is toasted, the pouch can be raised by the grasper and removed. The squeegees can be extended above the slice to ensure it doesn't move with the pouch as the pouch is raised.
In some embodiments an ingredient to be heated can be suspended from one or more wires or other filaments (e.g., passing through the ingredient and forming one or more closed loops, or loops with larger, anchored, or supported ends), which may be attached to the pouch (e.g., near its top) so that it is accessible to heating apparatus yet remains in a controlled position. The heating apparatus can include at least one surface brought into contact with the ingredient, or producing infrared radiation, a source of microwave or RF energy, hot gas or liquid, a laser, a steam generator, and others. If the wires are thin and easily broken, raising the pouch as described with the squeegees extended break the wire to allow release of the ingredient.
In some embodiments of the apparatus, ingredients can be heated, grilled, or otherwise cooked in a non-contact fashion (e.g., via indirect contact with one or more heated surfaces, through the pouch walls) as depicted in the cross-sectional elevation views of
In
If the ingredient is cooked by the plates, juices 932 may collect at the bottom of the pouch (this area may be isolated using a discontinuous or porous seal below the ingredient (not shown), such that the ingredient is suspended and the juices collect beneath it) or if the bottom is perforated or porous, or peeled open (plate pressure will retain the ingredient), juices will drip into a waste bin below. Once juices have been captured, a dish can be moved underneath the inner pouch and the pouch peeled open to release the ingredient onto the dish.
In some embodiments the inner pouch may include openings (e.g., open sides, slots or other perforations) which allow for the ingredient within, or portions thereof, to be released at the appropriate time without having to open the pouch. Perforations in the inner pouch can allow liquids, gasses, and/or ingredients or particles smaller than the perforations to enter or exit the inner pouch. For example, potatoes, rice, or pasta may be packaged within an inner pouch having the form of a mesh, then lowered into a container of boiling water for cooking once the outer pouch has been peeled and pulled out of the way.
The discontinuous (or porous) seal between the liquid and ingredient compartments may be peelable, allowing the ingredient to be removed after cooking. Since the seal is discontinuous, liquids within the ingredient compartment can enter the liquid compartment during cooking.
Some filter materials may be food-safe and be effective wet as well as dry, in which case seal 944—provided to avoid contact between the ingredient and the filter—may be unnecessary. If provided, seal 944 may be peelable or rupturable so it can be opened by the expansion of steam, etc. generated by heating the ingredient and/or liquid in the ingredient and/or liquid compartments, or by compressing one or both of those compartments within the apparatus (especially if they are pre-filled with gas such as air). Once seal 944 has been opened, the filter material should not detach and descend into the ingredient compartment. This can be achieved—assuming the filter material remains a continuous, non-shedding mass—by providing a discontinuous or porous seal below the filter, or by sealing/bonding the filter to at least one pouch wall. If the filter material can shed or otherwise break apart, then it can be contained above or within a material having pores fine enough to hold back the filter material, but allow grease, etc. to pass through.
At the top of the pouch peelable seal 950 is provided in some embodiments (e.g., those in which seal 944 is not used), above which are one or more pre-made holes 954 to vent emissions which have been filtered, allowing them to escape the pouch. Emissions may also vent through a porous upper region of the pouch if provided, or the upper region of the pouch may be pierced within the apparatus (e.g., by one or more needles) to allow venting. Since seal 950 (or seal 944) is peelable/rupturable, other seals in the pouch subject to the same pressure should be stronger. An exhaust duct with fan to generate airflow may be provided in some embodiments near the top of the pouch to collect emissions from the pouch.
As an example of using the pouch of
The pouch of
Alternatively, in some embodiments, the controller may cause the pouch to be clamped between ingredient and liquid compartments so as to prevent communication between them (and thus leakage from the liquid compartment), or the pouch may be sealed between the compartments (e.g., heat sealed in this region using heated jaws). The controller may then open the pouch at its top or elsewhere (e.g., the pouch may be slit beyond a peelable seal that can be opened) and when tilted or inverted so as to deliver the ingredient to a dish. After this, the controller may cause the pouch to be returned to an upright position, unclamped, and disposed of (e.g., dropped into a waste bin), possibly after sealing the pouch. In some embodiments the pouch of
In
In
In
In
In
In some embodiments the fixed plate inner surface is oriented at a smaller angle to the horizontal such that the ingredient does not slide on its own. The cover over the fixed plate can then be advanced downwards (e.g., using a gripper, rolling it up onto a take-up roller) and serve as a conveyor belt as in
Since cooking takes time (e.g., 5-7 minutes for a hamburger patty), in some embodiments the grill plates move out from under the dispenser (e.g., off to the side), allowing the dispenser to dispense other ingredients that may be needed (bun, tomatoes, sauce, etc.). The mechanism that moves the moveable plate as shown in 61(e) need not travel with the plates, since the plate can due to its weight remain in position.
In some embodiments multiple plate pairs forming a ring-shaped carousel are used, such that as the ring rotates from position to position, ingredients are added to plate pairs and then are processed and removed while the ring continues to rotate. Such a system is able to randomly access any plate pair to add an ingredient or allow it to exit (e.g., facilitating different cooking times). However, the ring can also index at a constant speed, with the first ingredients to be added being the first to be removed (first-in, first-out). The plates of
In some embodiments, ingredients 988 skewered on sticks 990 (e.g., disposable wooden sticks as used in shish kabob, yakitori) may be cooked in an automated system in a manner that does not contaminate the apparatus as shown in
In some embodiments ingredients on skewers can be cooked without transferring the skewers to a rotisserie (e.g., while vertical). Ingredients can be pierced by skewers/wires (e.g., vertical) and fall off of these (or be pushed off) into a dish after cooking, or the skewers may be released such that the ingredients fall into the dish while still on skewers. If the ingredient would normally slide off the wire, this can be prevented initially by ensuring that the ingredient is supported by the dish. Skewers (or wires) can be released by various methods, e.g., their tops may be embedded within the pouch above the compartment holding the ingredient, and once the pouch is peeled in that region, the skewer is released. If skewers do not rotate as they would if using a rotisserie, then heating means such as heating elements can be used—preferably arranged on both sides of the group of skewers (i.e., moved into place after the pouch is peeled)—to evenly cook the ingredients.
In some embodiments, ingredients (e.g., in a pouch or dish (e.g., if metal)) can be heated or cooked using a flameless heater such as SpeedHeat (Sterno Products, Corona, Calif.).
In some embodiments forced convection can be used to heat, cook, toast, and/or re-crisp ingredients (e.g., in a dish), similar to the way an air fryer, convection oven, or halogen oven works. Ingredients can be supported during heating in some embodiments by or one or more wires (e.g., 2 underneath, or 3-4 at different angles) that are fed from supply spools (e.g., to take-up spools, or they can be cut and dropped into a waste bin) such that for each new meal, the wires are advanced to a fresh section. In other embodiments ingredients can be supported while resting on raised ribs on a disposable foil tray (e.g., in which the ingredients are served) which allow air flow beneath the ingredients to heat them on the underside.
Using RF energy (e.g., from Goji Food Solutions Ltd., Hamilton, Bermuda or NXP Semiconductors, Eindhoven, The Netherlands) ingredients can in some embodiments be heated or cooked while within pouches or after being dispensed into dishes. This can be done selectively/differentially, thus for example all ingredients to be served can be dispensed onto a dish and then only some of them can be heated, and ingredients can be heated with different temperatures and times. This can avoid the need to dispense some ingredients, heat them, and then dispense other ingredients which are not to be heated. Precisely-beamed RF energy can be used to heat an ingredient inside a pouch while it is being transported to the dispenser, or to selectively heat one or more ingredients within a dish while the dish is still under the dispenser (the latter may also be achieved with other heating methods such as microwave). RF energy can also be used to selectively heat water in a pouch so as to steam an ingredient without directly cooking it.
Other methods of heating and cooking ingredients include resistive high-frequency heating, in which the skin effect is exploited to sear/crisp an ingredient, and variable peak wavelength cooking (Brava Home, Calif., US patent application US20170223774A1).
In some embodiments pouches or dishes containing ingredients are placed in microwave/RF chambers to be heated for pouches or dishes. Such chambers may be designed to be loaded or unloaded from the top, side, or bottom, and generally will include a door or other barrier. In the case of RF chambers, to the extent that RF energy can be precisely beamed, a fully-enclosed chamber may be unnecessary.
An ingredient may be heated or cooked by more than one method, either sequentially or simultaneously. For example, a chicken breast may be heated on its underside by placing it into a disposable foil dish in contact (e.g., enhanced by vacuum) with a heated chuck. Meanwhile, a radiant heater (e.g., a quartz infrared heat lamp) above the dish may be used to heat its upper surface. Thus, one side is heated by conduction while the other side is heated by radiation (of if the upper surface is exposed to hot air, then by convection).
In some embodiments a pouch design with multiple compartments may be used for steaming an ingredient: water may be contained in the lower compartment and heated (e.g., by direct application of microwave or RF energy, or by contact with a heated surface) and an ingredient to be steam in the upper compartment. Steam produced by the water rises through the channels into the upper chamber. Once the steaming is completed, the pouch can be partially peeled so as to release the water into a waste bin, etc., after which the ingredient can be released into a dish by peeling the pouch further.
In some embodiments, ingredients may be boiled, braised, soaked (e.g., beans), have their flavor contribute to a broth, etc. by using a similar two-compartment pouch. The pouch contains liquid (e.g., water) which fills both the lower compartment and at least a portion of the upper compartment, while the latter contains the ingredients, which are at least partially immersed. The liquid can be introduced during the packaging process, or later (e.g., by piercing the pouch with a needle). In some situations (e.g., boiling pasta or a grain), the goal is to retain the ingredients in the upper compartment and dispose of or separately utilize the liquid, while in other situations (e.g., making soup), the goal is to retain the liquid while disposing of or separately utilizing the ingredients (e.g., chicken, bay leaves, a tea bag) in the upper compartment, and in some situations both the liquid and ingredients are to be retained but need to be dispensed into different vessels. After cooking, the lower compartment is opened, releasing the liquid (e.g., into a waste bin, bowl, or secondary pouch) after which the upper compartment may be opened to release its contents (if these contents are to be disposed of, there may be no need to first release them, however).
Pouches (e.g., polymer) may comprise conductive (e.g., metal foil or wire) patterns of electrodes/antennas which provide for resistive (DC/low-frequency) or RF/dielectric (high frequency) heating of an ingredient within. If intimate contact between the conductive patterns and the ingredient is desired, the pouch can be vacuum packed. To facilitate recycling, the conductive patterns may be separable from other portions of the pouch (e.g., may be sandwiched between the ingredient and the polymer pouch walls).
In some embodiments an ingredient in a pouch may only be partially cooked (e.g., seared) by methods and apparatus such as those described above.
If cooking in an open vessel, steam, splatter, oil droplets, etc. may rise up and contaminate the dispenser and other equipment. To minimize the risk of this, in some embodiments air flow (e.g., generated by one or more air knives or vacuum plenums) is arranged to flow across the vessel (e.g., horizontally), such that such contaminants are diverted from their normal trajectories and rarely if even end up on surfaces they would contaminate.
In some embodiments ingredients may be heated, cooked, toasted, crisped, etc. while inside a heat-resistant pouch, or after transfer to a sleeve that is heat-resistant and preferably, disposable. Materials which can be used include metal foil, metal mesh, PET, fiberglass, and PTFE-coated fiberglass.
Ingredients, especially those in pouches containing little or no air, can be heated in-pouch by immersion into hot water, or using steam. Prior to opening the pouch, if desired the outside of the pouch can be dried by hot air (e.g., via an air knife, shaking, centrifugation, drying similar to that of an Airblade (Dyson, Malmesbury, Wiltshire, United Kingdom), contact with an absorbent material, etc. To minimize the need for drying, the pouch exterior can have a hydrophobic coating, or be surrounded by another pouch that isolates it from water or steam. In the case of hot water, the first (ingredient-containing) pouch can be lowered into a second pouch surrounded by hot water whose bottom is preferably anchored so it remains submerged. Hydrostatic pressure will push out air between the two pouches, providing intimate contact and good thermal contact between the first pouch and the water. To facilitate placing the first pouch inside the second, the latter can be lifted out of the water temporarily, or water can be introduced afterwards; actuated tabs may also help open the second pouch.
Other methods of heating and cooking that may be used include cooking by electroporation and pulsed ohmic heating (IXL Netherlands, Schalkwijk, The Netherlands); high intensity focused ultrasound energy (known to the medical art); in-pouch vigorous agitation, manipulation, tumbling, etc.; and injecting steam or hot water into the pouch (and optionally tumbling).
Other Processing
Some foods may benefit (at least aesthetically) from having an ingredient introduced by swirling, mixing, etc. once at least another ingredient has been introduced into a dish or other vessel. For example, a soup can be dispensed into a bowl (preferably first adding any solid ingredients to the bowl to avoid splashing) and then a cream, yogurt, etc. can be dispensed onto the surface and swirled into the soup using a disposable tool such as a plastic or wood stick held in a holder (e.g., clamped by a solenoid). The bowl can be moved under the tool (or vice versa) with two axes of motion to achieve the desired swirl, etc. Once the bowl has moved away (e.g., to be served), the tool can be released into a waste bin below. A new stick can be delivered (e.g., from a magazine) into the holder when needed. A similar approach using a disposable tool can be exploited for mixing, blending, stirring, breaking up/dispersing, etc. ingredients within a vessel (e.g., as part of the process of preparing a meal).
If at least one compartment of a pouch contains a gas such as air or a modified atmosphere (to preserve freshness), or a flowable liquid, peelable or burstable seals can be opened in some embodiments by applying pressure to the compartment. The seal can be between the compartment and the outside, or can be an internal seal between multiple compartments within the pouch. Once an internal seal is opened, the contents of multiple compartments may be combined (e.g. mixed, stirred) and may interact. Inter-mixing can be encouraged by shaking or vibrating the pouch, by tilting it (e.g., multiple times) or tumbling it, by pressing on the pouch or rolling/dragging across it using one or more rollers or other shapes, etc. In some embodiments, compartments with items to be combined are not adjacent to one another, but are separated by a compartment intended for mixing. Examples of ingredients that can be combined in a pouch are flour and water used to make a roll or pizza crust, salad greens and salad dressing, eggs and vegetables used to cook a frittata, etc.
Pouch Disposal
In some embodiments it is preferable to dispose of a pouch by dropping it from the grasper into a bin (e.g., refrigerated) below the dispenser than to lift it out of the dispenser and move it to a bin. Dropping it is quicker and minimizes the risk of an ingredient dripping from or falling off of an open pouch during transport and onto the machine, contaminating it. Before dropping the pouch, it may be lowered until closer to the bin (or partway inside of it) to make sure that it goes entirely into the bin (and air resistance or currents do not disturb this).
If a bin is located below the dispenser and below the dish, the dish can move out of the way (e.g., along one or more tracks that do not obscure the bin), and then return to being under the dispenser. The bin may also be located alongside the dish, and optionally move along with it. The bin can also be used to receive undesired contents of pouches (unwanted amount of ingredient, liquid), drippings from cooking, etc. More than one bin can be used in some embodiments, e.g., one for relatively empty pouches, one for liquids and solid waste (unwanted amounts of ingredients). In the system shown in FIG. 29(b) of the 074 and 253 filings, multiple bins can be provided, one below each dispenser.
Dish Transport and Delivery
The delivery box described in the 074 and 253 filings can also serve as a heater such as a microwave oven: a dish can enter, be heated, and if any additional ingredients need to be added, it can leave the delivery box, move to one or more dispensers, and then return to the box for delivery to the customer. The box or a similar box may incorporate a double door/airlock and be positively pressurized and/or have high velocity airflow to prevent the entrance of insects or other vermin. Machine vision may be used to verify that no undesired “visitors” have entered the box before it is opened to the inside of the machine. Delivery boxes may be stacked vertically and completed meals introduced in one boxes using an elevator-type device.
In some embodiments, rather than have dishes move in a sequential fashion as in FIG. 29(b) of the 074 and 253 filings, dishes may be moved by the system controller to and from dispensers independent of one another on “smart” carriers in a random-access (vs. serial) fashion. Such carriers can bring dishes only to the dispensers (or other subsystems, such as heaters) needed for a particular customer recipe/order, and in the required sequence. Carriers may be wheeled or slide, driven by motors, linear motors (e.g., Sawyer-effect 2-axis linear motors), etc. In some embodiments one or more robots (Cartesian, SCARA, etc.) can manipulate the carriers (e.g., from below using magnets) in a pick and place fashion. In systems with independently-moving bowls, the controller must coordinate the motion of the bowls to avoid any collisions, and holes can be provided below dispensers that provide access to one or more waste bins. The carrier paths can be designed so that any portion of the carrier (e.g., wheels) that might fall into a hole avoids it instead.
To determine how much of the contents of a pouch are dispensed, the dispenser may have a built-in weighing capability similar to that of FIG. 22(d) of the 074 and 253 filings, by incorporating a load cell or spring/linear scale (which also provides compliance/tension control) into the assembly above the grasper, and/or the dish carrier may incorporate weighing capability (e.g., load cell).
Restocking
Systems for automated food preparation, especially if deployed in public spaces, can be restocked manually but also by robotic, remotely-controlled or autonomous resupply vehicles. For example, a system can be located out of doors and resupplied by a rolling delivery vehicle, or by an air vehicle (e.g., quadcopter) or boat-like vehicle that delivers individual pouches, groups of pouches, shelves filled with pouches, etc. For example, a quadcopter can drop pouches into a funnel or net one at a time, or feed a pouch chain to an outdoor system, without even needing to land. Systems that are indoors, if located adjacent to an exterior wall, may be restocked by a delivery vehicle that accesses the system through a hole (e.g., closeable) in the wall. To minimize the size of this hole, individual pouches may be used for restocking, or pouch chains (which may be separated using perforations, scoring, or by cutting within the system, if the system uses individual pouches rather than chains). If individual pouches are delivered to the system, it can identify them and place them into shelf cubbies or other storage units using the same manipulator it uses to fetch them later (e.g., using paddle 332); this can be done when the system is idle (e.g., early morning). Whether resupplied by a human or a machine, it is desirable that the resupply process take as little time as possible, so that many other systems can be resupplied on the same day.
Automated shuttles/drones (airborne, rolling on the ground, sailing on water) can bring ingredients needed by one machine to another machine, and to/from commissaries or other locations where ingredients are prepared and/or packaged. For example, an ingredient that is in demand (generally, or as the result of at least one pre-order) at one machine but less in demand at another machine can be moved from one to another by an autonomous device.
In machines having shelves comprised of modules, or using pouch boxes, since modules and boxes can be removed independently, then the machine in some embodiments can ‘defragment’ storage so that it keeps pouches in as few modules or boxes as possible, thus freeing others (or filling them with pouches to be removed due to them not selling, being close to expiration, etc.) to be removed and replaced with modules or boxes with new/fresher/more pouches. Defragging can also facilitate/accelerate pouch fetching by the grasper, and machine servicing tasks such as loading and unloading ingredients.
The MEP may be part of the shelving unit: an area reserved for pouches that are soon to be used for one or more meals. Once an order is placed but it is not yet time to prepare it, the machine can create/allocate a MEP for that particular order. Space may be provided for multiple, simultaneous MEPs.
In some embodiments the machine may be restocked by merely placing inside the machine within reach of the grasper a box, case, etc. containing pouches, which may be randomly piled inside. The controller can then direct the grasper to fetch each pouch from the box and using a scanner (e.g., barcode) and/or machine vision, identify each pouch, verify it and its contents are acceptable, and then place it in a known location within the shelf or pouch box. This operation can be done during idle times, when the machine is not preparing a meal for a customer.
Once a shelf module has been inserted or replaced, the codes on all of its pouches can be scanned, after which it is ready to use. If, however, it is known to the machine generally in which region of the machine to find a particular ingredient, the machine may select a pouch within that region, and then read the code to verify the identify, expiration date, etc. of the ingredient.
If a pouch has an ingredient that is only partially consumed (e.g., a multi-compartment pouch, or a pouch that has been resealed), it can be replaced in the shelf or box. If the pouch has been resealed, a new expiration date can be established by the machine controller based on ingredient data and in recognition that the pouch may have been packaged under vacuum or a modified atmosphere, and these conditions may no longer exist in the resealed pouch (although in some embodiments the machine may vacuum reseal the pouch after evacuating air inside and/or backfilling with a modified atmosphere gas).
Cooking Vessels
Vessels with detachable liners such as those shown in FIGS. 10,20, and 31 of the 074 and 253 filings are provided with vacuum in some embodiments since in many cases if vacuum is not applied between the wall of a heated vessel and its liner, thermal conduction between vessel and liner can be poor due to the insulating layer of air between them, reducing efficiency, slowing heating and cooling, and limiting the temperature that the liner can practically attain. The liner is preferably thin (e.g., 0.0005-0.0050″ inch) and made of low-cost, heat-stable and food-compatible materials such as aluminum foil, anodized aluminum foil, or stainless-steel foil) so that it can readily be disposed of. Due to its small thickness, it might normally be fragile were it not held in intimate contact with the vessel wall through the use of vacuum, the wall thus also providing mechanical support. Liners (or if no liner is used, then vessels without liners), may be provided with small openings (e.g., widely spaced, or contiguous, as with a screen or mesh) or with a membrane or porous/filter material. Such liners may be used for procedures such as frying that may generate steam or gasses which should be allowed to escape. Openings can be made using laser or mechanical drilling, by stamping, by fixing a mesh over a larger hole, etc. While allowing steam and/or gasses to escape, such a liner/vessel can retain droplets such as oil which should be keep inside the cooking environment to avoid contamination of the system.
In some embodiments rather than vacuum between vessel and liner, a thermally-conductive liquid, gel, or soft elastomer may be used. Flowable materials such as water (e.g., under pressure to avoid steam evolution, possibly superheated), or a high-temperature stable working fluid may also be introduced into the space between vessel and liner in order to heat or cool the liner. In some embodiments the volume between the vessel wall and liner can behave similar to a heat pipe in which heat is transferred from vessel to liner via an evaporating liquid such as water, which then condenses on the liner, heating it; condensed liquid then returns to the vessel surface and is evaporated again. In some embodiments liners may be heated using jets of fluid (e.g., steam or hot air jets), or by using inductive heating (e.g., using a liner containing a ferromagnetic or relatively low electrical conductivity material).
In FIG. 20(a) of the 074 and 253 filings, a “clamshell”-like arrangement of vessels is shown. The bases depicted may incorporate channels for vacuum which can be communicated to the lower base through a rotating vacuum fitting, and to the upper base via such a fitting or flexible tubing.
To reduce the possibility of adhesion to a liner such as liner 678 (FIGS. 20(a)-(j) of the 074 and 253 filings), ingredients which tend to adhere if completely raw (e.g., meat) may be cooked partially, at least on their surfaces. In some embodiments a single-use scraper (e.g., plastic, or plastic with a metal edge) can be provided to help detach adherent ingredients. Vessels such as those in FIGS. 31(a)-(l) of the 074 and 253 filings may contain actively or passively driven elements (e.g., a washable, passively driven weighted scraper attached to a pivot) which serve to mix or scrape ingredients (to prevent sticking, in the case of raw meats or eggs, etc.), e.g. while the vessel is rotating.
With respect to liners such as 678, in cases in which heat is supplied by other means (e.g., radiation, convection) and not by conduction, a heat source adjacent the liner and a vacuum to provide close contact between heat source and liner is not needed.
Miscellaneous
In some embodiments the dish or cooking vessel into which ingredients are dispensed already has one (or more, if mutually non-interacting) ingredient in it, such that the dish serves as a food storage device (in lieu of a pouch) as well. As an example, an acai bowl might be prepared using a bowl in which refrigerated/frozen acai is already packed into the bottom of the bowl; to this could then be added various topping. Ingredients in the dish can be sealed within by a peelable film, etc. This approach may be useful for example when it is difficult to dispense the ingredient into a dish in a way that a) delivers it entirely into the dish; and/or b) has it properly placed or shaped within the dish.
The system controller can prevent food sales from the machine if temperature ever rises above a particular level for too long a time, and notify the appropriate personnel.
The machine can include an uninterruptable power supply to prepare for possible power outages and to allow the machine to be temporarily disconnected for transport without first removing the ingredients within. While operating on battery, machine functions other than refrigeration and critical sensing, data logging, and communication (with parties responsible for tending to the machine) may be disabled. The system may include a variety of temperature sensors, such as those which monitor ingredient temperatures. If monitored temperatures become too high or too low (signaling possible freezing) for too long (e.g., due to malfunction or power loss), the affected ingredients can be identified and disposed of if needed.
In some embodiments the machine can prepare frozen desserts (e.g., ice cream, sorbet, custard, yogurt) as follows: The dessert mix in liquid form can be initially within a pouch. Upon opening the pouch, the mix can be dispensed onto a cold plate (e.g., covered by a thin, disposable film which may be held tightly against the surface by vacuum) and a disposable or cleanable spatula can be used to scrape the frozen mix off the plate and into a bowl for Thai-style rolled ice cream, etc. Or, the mix can be dispensed onto a disposable film and the film manipulated (e.g., bent, passed around a blade as in
The machine can adapt the meals which are offered according to ingredients available or which should be consumed first (based on expected expiration and/or general or machine/location-specific usage patterns), and offer substitutions to the customer, and can also refer customers directly or through a mobile app or web site to another nearby machine if what they want is not available.
“On the side” ingredients that are always delivered directly in a pouch to a customer can be contained in pouches that are intended for customer use (e.g., size, shape, graphics, method of opening) rather than for machine use, and may be stored within the machine in the same shelf, pouch box, etc. in some embodiments, or in other storage locations if not compatible with such storage. In some embodiments a pouch intended for machine use but containing an ingredient a customer requests to be “on the side” can be delivered (e.g., dropping the pouch down a chute) after a trimming operation which removes portions of the pouch (e.g. reduces the size of flaps) that are not needed by the customer or would be suboptimal.
The machine can include a “black box” comprising a data recorder that records images from the machine camera of every pouch before its contents are dispensed, every dish before it is served, pouch bar codes, and other photos (possibly photos of people in the vicinity of the machine, to help solve vandalism crimes), as well as data collected by various sensors. This data can be transmitted as needed (for pouches that a machine vision system determines are questionable) and/or periodically.
When dispensing an ingredient into a dish into wish at least one other ingredient has already been dispensed, it can be advantageous to determine the configuration (e.g., 2D or 3D size, shape, location, orientation) of previously-dispensed ingredients, as this can be difficult to predict since the exact configuration of an ingredient may depend on the conditions under which it was dispensed, interaction with other ingredients and with the dish or other vessel, movement (e.g., slumping) of the ingredient one dispensed, etc. If the configuration can be determined, then the deposition of subsequent ingredients can be adjusted to achieve the desired outcome. For example, in preparing a burrito bowl or salad, it may be desirable to dispense an ingredient in a specific region of the dish offering more space for that ingredient, rather than pile one ingredient upon another. In another example, when making a sandwich, accurately determining the configuration of a previously-dispensed bun or bread slice can allow a filling (e.g., tuna salad, cheese slice), condiment (e.g., mustard), or other ingredient to be dispensed correctly, by adjusting the position of the dish beneath the dispenser before and/or during the dispensing of the ingredient. With this approach, a cooked egg can be well-centered on a bagel, etc. The configuration of pre-dispensed ingredients—effectively creating a 2D or 3D map of what is in the dish, which may include grayscale or color information—can be determined using sensors known to the art such as cameras, 3D scanners, stereo cameras, time-of-flight sensors, and laser distance sensors (collectively, “scanners” in a process of “scanning”). Scanning may be done before an ingredient is dispensed and/or while an ingredient is being dispensed, since the configuration may change dynamically during dispensing (e.g., a previous ingredient may be moved by a new ingredient), and the dispensing may advantageously be made into a closed-loop process based on real-time sensing and feedback. Feedback may adaptively influence the apparatus to vary location and orientation of a dish, adjust the order in which ingredients are dispensed, modify the dispensing parameters such as squeezing speeds, etc. If scanning is before dispensing, then in some embodiments the dish can move to a position where it can be scanned without obstruction by the dispenser, etc. If scanning is during dispensing, then if impractical to scan from one vantage point due to obstructions, scans can be taken from multiple vantage points and the results combined. In some embodiments a clear or translucent dish (e.g., with a light above the dish) may be used to allow scanning from below. In some embodiments a scanner is attached to the dispenser or above the dispenser. Scanners may also be used to scan the final meal as prepared, for purposes of documentation, publicity, and quality control.
To produce a folded food product such as a burrito, a set of rotating plates may be used sequentially (similar in some respects to the plates of U.S. Pat. No. 5,912,035A) to fold a tortilla, etc. once one or more ingredients has been dispensed onto it. Each plate can be independently actuated, and the set of plates can be stationery (e.g., beneath a dispenser).
To prepare a taco, a dish (e.g., molded pulp) having a shape (e.g., letter “U”) that can support a crisp taco shell with its opening facing upwards or at an angle can be used, with ingredients dispensed directly into the shell. To prepare a taco using a soft tortilla, a dish having a shape (e.g., wide letter “V”) that keeps the tortilla mostly open but slightly folded may be similarly used.
Systems for automated food preparation may include frying subsystems such as air fryers (optionally having screens which confine the ingredient to be fried to a limited area while air circulates, avoiding system contamination) and deep fat fryers (e.g., with automated oil exchange and/or filtration/recycling).
Systems may be fully, partially, or not refrigerated depending on design, ingredients to be stored, and desired shelf life. In some embodiments systems are designed so some or all storage devices are refrigerated, but not the rest of the system, which can be more efficient and reduce system cost. For example, a storage device for pouches might be in the form of a heavily-insulated chamber (e.g., standard insulation, aerogel, vacuum), and a fetching mechanism (e.g., grasper 274) may be within the chamber, along with motion stages. The mechanism can then deliver a pouch requested by the controller to a port in the chamber (e.g., a revolving door which can bring the pouch from inside to outside while not opening the chamber) where another mechanism can take over.
Filling/sealing and weighing equipment known to the art of flexible packaging is difficult to use for loading many large solid ingredients (e.g., a slice of cheese or bread) into a pouch similar to
Food can be prepared for a customer in one of a multiplicity of automated machines/kiosks depending on the customer's preferred machine location and in a way that minimizes waste. An algorithm for facilitating the ordering process may include the following steps: 1) input the preferred location; 2) search the current ingredient inventory and expiration dates of the machine at that location; 3) compare packages having the soonest-to-expire ingredients with a recipe database and determine which recipes to offer; 4) offer recipes and solicit input; 5) if an offer is selected, prepare the food, or, if an offer is not selected, then offer additional recipes which require ingredients that will take longer to expire, and if an offer is selected, prepare the food.
Food can be prepared for a customer so that it is ready at exactly the time requested, without any wait, using an algorithm that may include the following steps: 1) input the customer's recipe selection and preferred machine location; 2) calculate the preparation time for the recipe (this can be done with great accuracy if dispensing times for given ingredients are programmed or measured in advance, if grasping/travel time for a given pouch to reach the dispenser, for heating, etc., is taken into account); 3) determine available time slots for the particular machine that accommodate the preparation time; 4) offer available pickup times to the customer and solicit input; 5) once a pickup time is selected, allocate the time slot accordingly to the customer's order; 6) monitor the customer interface for possible change requests; 7) if a change request is made, repeat beginning at step 3; 8) when the time slot start time arrives, start preparing the food. If the customer provides her location (e.g., via GPS) and possibly her mode of transportation to the machine, the algorithm can further suppress any pickup times that are too soon, and optionally modify the pickup time, automatically selecting another available time slot, if customer location and speed indications suggest that the customer will not arrive within a few minutes after her planned pickup time.
An algorithm can be used that inputs a customer's food selection, location (e.g., GPS coordinates), and desired distance, then executes steps that may include: 1) determine which machines within the specified distance have the required ingredients for the selection, optionally prioritizing those having ingredients closer to expiration; 2) calculate preparation time and identify available time slots for each nearby machine; 3) display a choice of machines and available pickup times for each machine, e.g., in order of increasing distance; 4) solicit and receive an order; 5) add the order to the selected time slot for the selected machine.
In some embodiments pouches may be made in which one flap is longer than the other, thus allowing one flap to be separated from another more easily. Such pouches may be made two across from film webs as shown in
Digital recipes used by automated food preparation systems can include ordinary recipe information regarding ingredients and quantities (number of pouches or pouch compartments, or fraction of a single compartment (though often pouches will have the pre-measured weight or volume required for the recipe, taking into account the number of servings)), but may also include: information required for dish/dispenser coordinated motion; locations and orientations of ingredients to be deposited within a receptacle; stirring or other manipulations to be performed within a receptacle; in-pouch processes to be performed, and associated parameters; heating and cooking (in-pouch, in-vessel, etc.) and associated parameters; type of dish for serving, and whether a lid is provided; whether to supply utensils with food, and which kind; whether the pouch needs to be drained of liquid (e.g., by partially opening it and allowing liquid to drain into a waste container) before dispensing, and for how long; for grilling, time, temperature, and plate pressure; for stir-frying or other tumble-cooking operations, the motion profile (displacement, speed, acceleration, type of motion, draining, etc.); which ingredients should be by default served ‘on the side’, etc.
In some embodiments it is desirable to dispense an flowable ingredient in a shape other than that which might be obtained by simply compressing the pouch and allowing the ingredient to issue through the opening at the bottom of the pouch compartment. For example, it can be more aesthetic to dispense such an ingredient in a spherical shape, suggesting that it was scooped out of a container, as is commonly done for ice cream, etc. While many other shapes are possible, a spherical shape will be assumed below. Methods of achieving such a shape include that of cross-sectional elevation view
A third approach to controlling the shape of a flowable ingredient during dispensing is to vary the shape and/or size of the pouch outlet during the dispensing process. For example, to deposit an ingredient in a spherical shape, the outlet can be initially small while the “south pole” of the sphere issues from the outlet, then gradually widen until reaching a maximum diameter at the “equator”, then gradually shrink again until the “north pole” is finally deposited. Such changes in size can be implemented using an actuated, adjustable hole size version of a casing (see casing 726 of the 074 and 253 filings)—e.g., a mechanical iris—which surrounds the pouch outlet and forces the flexible pouch walls to form a smaller size opening (or stretches the walls if the material is elastic), thereby varying the instantaneous cross section according to commands from the system controller.
Ramifications
In some embodiments sensing may be used to detect for example when the pouch is correctly positioned within the cubby to allow proper grasping, when the grasper has grasped the pouch, when the flaps of the pouch are moving along with the arms, when the flaps are between the lower and upper clamps and can be grasped by the peeler, when the flaps are securely grasped, etc.
Materials which come into contact with ingredients do not necessarily need to be disposed of or cleaned after a single use. In particular, in a system in which a limited number of ingredients (bread and cheese) comes into contact with the materials, and particularly if such materials become heated to a sterilizing temperature or can otherwise be sterilized, then such materials may be used multiple times.
In some embodiments in which a pouch is vacuum packed, it may be pierced, peeled, or otherwise opened by a small amount (e.g., near its top) before being peeled opened, to reduce pouch distortion and/or to allow the venting of gasses during heating of the ingredient therein.
In lieu of tensioning the pouch (e.g., using grippers as shown), the pouch flaps can become easier to separate/reorient by squeezing the pouch so that the contents (especially if flowable) are not able to distort the pouch as much due to their weight, etc. Squeezing can be performed in the area of the apex or above it.
In lieu of being supported from their top edges when moved (e.g., from storage to dispenser), pouches can be supported from at least one face (e.g., with suction cups), their vertical edges, or their flaps. During dispensing, pouches can be supported from their vertical edges and in some cases from their faces.
In some embodiments a second set of squeegees or rollers near the bottom of the pouch may be provided to serve as a valve, which can increase control over dispensing food items such as those of Type 1.
Dispensers such as those described herein can be configured so that the top of the pouch does not move downward during peeling of the pouch. Rather, the pouch walls are peeled upwards such that the peel front moves upwards as more and more film is peeled. Blades such as those of
Ingredients can be in various formed: raw, cooked, partially-cooked, dehydrated, freeze-dried, etc. If dehydrated or freeze-dried, they can be reconstituted by the addition of water (e.g., hot).
Sensors may be incorporated into systems using to evaluate nutritional content, quality, taste (e.g., sweetness) and other attributes of ingredients, to find contaminants, detect pouch breach, identify spoilage and pathogens, etc. For example, measuring pouch thickness, height, or width can identify pouch inflation due to gasses which may indicate spoilage. Sensing modalities may include spectroscopy (e.g., near infrared spectrometers from Consumer Physics, Herzliya, Israel); X-ray imaging systems; metal detectors; ultrasonic systems; cameras; machine vision systems; weight, volume, and dimensional sensors; mechanical compliance sensors; etc. Ingredient evaluations can be performed as ingredients are introduced into the system, while in storage, just before use, etc.
In some embodiments blades (or peeling rollers) may be moveable with respect to the dispenser. For example, they may be mounted to linear bearings or flexures and urged downwards (e.g., by their own weight), allowing them to move in a way that allows them to press against the film surface and maintain a desired tension on the film as it passes around them. Or, they can be moved by suitable actuators into different positions or orientations to optimize delivery for particular ingredients.
In some embodiments, in lieu of a carousel (e.g. FIGS. 31(a)-(l) of the 074 and 253 filings) holding individual pouches, ingredients may be stored in other ways, including other structures which hold individual pouches, or approaches using pouch chains/multi-compartment pouches (e.g., chains containing multiple ingredients arranged in the order required by a particular recipe).
The appliance shown in FIGS. 31(a)-(l) of the 074 and 253 filings can be provided with a set of pouches arranged linearly, e.g., in a box, such that pouches are selectively accessed by sliding them linearly. In addition to reusable pouches already described, and other reusable containers (e.g., trays with film lids held in place by resealable seals, magnets, etc.), the appliance (and the system of FIGS. 19(a)-(l)) in the 074 and 253 filings) can use pre-loaded pouches with disposable/recyclable film. Such pouches, containing the ingredients for one or more meals, can be grouped/ganged together (e.g., into a box) at least temporarily, to allow them to be loaded (and optionally, unloaded) into the appliance all at once, and also stored in a refrigerator before use. The box can be collapsible, with the pouches remaining inside, for easy return after use.
Sensors may be incorporated into the machine for a variety of purposes. For example, if the flaps of a pouch are not successfully separated/reoriented, this can be detected by flap sensors (e.g., near/within the peeler clamps of
Pouches may contain chemicals for self-heating (e.g., as in U.S. Pat. No. 6,289,889) or cooling the ingredients, a process that can be initiated, e.g., by using a roller or clamp to crush a portion of the pouch holding the chemicals or rupture a frangible seal.
Pouches may have flaps that are initially joined together to provide robustness in handling, such as having corner or bottom regions that are sealed, with such regions cut off, or the seal holding them weakened (e.g., if made with a light-degradable adhesive) before the flaps are separated. Flaps may be fully sealed together initially, and forced apart by powerful suction, seal weakening, etc.
TerminologyThe term “ingredient” or “ingredients” refers to one or more distinct, edible food items used in the preparation of an item to be consumed, and the term “food product” or “food products” refers to one or more edible food items ready to be consumed. The singular and plural forms of both phrases may be considered interchangeable, and the phrases themselves may not always be strictly applied herein and may be considered at least in some situations to be interchangeable.
The terms “food item” and “substance” are generally used as synonyms for the term “ingredient”.
The term “pouch” generally refers to a flexible package comprised of one or more materials in film form such as polymers and/or metals, but may be understood in some cases to refer to other containers, including ones which are more rigid.
The term “vessel” generally refers to a container able to hold ingredients/food products for purposes of storage, processing delivery/presentation/consumption, etc. and may be interchanged in many cases with other containers having similar functionality.
The term “dish” generally refers to a receptacle or vessel for serving or eating or drinking food, such as bowls, plates, cups, mugs, and glasses.
The term “meal” generally refers to one or more food items delivered for consumption, possibly involving processing of various kinds.
“Proximate” or “in proximity to” generally refers to close enough to achieve the required functional purpose, for example, in the context of a dispenser or dispensing system, it refers to a distance comparable to a dimension of a typical pouch and more preferably within a smaller distance.
As used herein, words of approximation such as, without limitation, “about”, “substantial” or “substantially” refers to a condition that when so modified is understood to not necessarily be absolute or perfect but would be considered close enough to those of ordinary skill in the art to warrant designating the condition as being present. The extent to which the description may vary will depend on how great a change can be instituted and still have one of ordinary skilled in the art recognize the modified feature as still having the required characteristics and capabilities of the unmodified feature.
GENERALFigures within this application are not necessarily to scale.
Motions are considered relative. Thus, if object A moves relative to object B which is at rest, the equivalent effect of object B moving relative to object A which is at rest is also contemplated in the disclosure.
It will be understood that particular embodiments described herein are shown by way of illustration and not as limitations of the disclosure. The principal features of this disclosure can be employed in various embodiments without departing from the scope of the disclosure. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this disclosure and are covered by the claims.
It is intended that the aspects of the invention set forth herein represent independent invention descriptions which Applicant contemplates as full and complete invention descriptions that Applicant believes may be set forth as independent claims without need of importing additional limitations or elements, from other embodiments or aspects set forth herein, for interpretation or clarification other than when explicitly set forth in such independent claims once written. It is also understood that any variations of the aspects set forth herein represent individual and separate features that may form separate independent claims, be individually added to independent claims, or added as dependent claims to further define an invention being claimed by those respective dependent claims should they be written.
In view of the teachings herein, many further embodiments, alternatives in design and uses of the embodiments of the instant invention will be apparent to those of skill in the art. As such, it is not intended that the invention be limited to the particular illustrative embodiments, alternatives, and uses described above but instead that it be solely limited by the claims presented hereafter.
Claims
1. A method for dispensing at least one substance from a sealed flexible package, comprising:
- (a) providing a sealed flexible package containing at least one substance wherein the package comprises at least one flexible film comprising a left portion and a right portion with each portion having an inside and an outside surface with the inside surfaces facing each other and wherein the portions are partially sealed to one another to form at least one cavity containing the at least one substance and wherein the seal comprises at least one openable seal and wherein each portion comprises an unsealed extension at one end and wherein each extension is narrower than a sealed region of the portion from which it extends;
- (b) grasping the extension of the left portion using first grasping means;
- (c) grasping the extension of the right portion using second grasping means;
- (d) moving the first and second grasping means to pull the two extensions away from one another;
- whereby the seal is opened and at least a portion of the at least one substance is dispensed from the cavity.
2. The method of claim 1 wherein the first and second grasping means move along a path that is at least partially curved.
3. The method of claim 1 wherein the first and second grasping means each comprise a clamp having leading and trailing portions.
4. The method of claim 1 wherein the first and second grasping means move substantially below the flexible package when grasping the extensions.
5. A method for dispensing a food ingredient from a package, comprising:
- (a) providing a sealed package containing a food ingredient wherein the package comprises at least one flexible film comprising a left portion and a right portion with each portion having an inside and an outside surface with the inside surfaces facing each other and at least a portion of the inside surfaces contacting the ingredient and wherein the portions are sealed to one another to form at least one cavity containing the at least one ingredient and wherein adjacent to the at least one ingredient, the sealing comprises at least one openable region and wherein the package comprises two opposite edges and two unsealed flaps beneath the seal;
- (b) gripping the package near the two edges and pulling outwardly on the package to apply tension to it;
- (c) separating and reorienting the flaps;
- (d) clamping the flaps and applying tension to them;
- wherein the package is opened.
6. The method of claim 5 wherein the seal comprises a chevron having an apex at its bottom and wherein the gripping is substantially at or lower than the height of the apex.
7. A method for opening a flexible package, comprising:
- (a) providing a package having two flaps with non-aligned apertures;
- (b) inserting pins through the apertures of the flaps;
- (c) moving the pins to separate the flaps;
- whereby the package is opened.
8. The method of claim 7 further comprising grasping the separated flaps and applying tension to them.
Type: Application
Filed: Nov 6, 2018
Publication Date: May 2, 2019
Inventor: Adam Cohen (Dallas, TX)
Application Number: 16/182,563
