Abstract:
An ice pop making apparatus for rapid or “on demand” ice pop production involves an apparatus and method whereby one or more mold inserts are removable from the ice pop making apparatus subsequent to an edible product being frozen in the mold insert. The mold insert is exposed to ambient conditions or a fluid bath or stream to release the edible material from the mold insert. The mold insert may be cleaned and/or filled remotely from the ice pop making apparatus so that the ice pop making apparatus will be kept clean and there is no cross-contamination of edible products or flavors between consecutive batches of ice pops.

Description:
[0001]    This application claims the benefit of U.S. Provisional Application No. 61/443,006, filed Feb. 15, 2011. 
     
    
     SUMMARY 
       [0002]    The present disclosure is directed to an ice pop making apparatus. More particularly, the disclosure relates to an apparatus to facilitate and speed the freezing of an edible material on a stick via a refrigerant media. The apparatus and method also comprises the subsequent removal of one or more mold inserts containing the frozen edible material from the apparatus. The independent, selectively removable mold insert permits the ready removal of the frozen edible material from the apparatus thereby simplifying operation of the apparatus and providing a sanitary and easy-to-clean unit. The mold insert can then be exposed to ambient conditions or a fluid bath or stream to release the edible material from the mold insert. 
       BACKGROUND 
       [0003]    Ice cream and ice pops are commercially-made, frozen confections. There has been an on-going interest in producing home-made ice cream. However, there have been very few products to effectively produce ice pops in the home in an expedited manner. Conventional ice pop makers require a user to leave a fluid drink or mixture in a freezer for an extended period of time. These conventional ice pop makers do not provide instantaneous or near instantaneous gratification. It can take hours for the desired product to freeze into the desired ice pop. In other words, they are not “on demand” or quick ice pop makers. 
         [0004]    There are a number of technical challenges to providing ice pops in mere minutes that have yet to be effectively solved. For instance, even where known equipment can quickly produce an ice pop, it can be very difficult to remove the ice pop from the ice pop-making apparatus. In fact, one item of conventional wisdom is that an extraction tool is needed in order to get the frozen material out of the ice pop making apparatus. 
         [0005]    Known devices could also be more sanitary and easier to clean. Currently, the edible product that is to be frozen in a quick freeze ice pop maker is placed directly into the apparatus. Residue of the ice pop remains in the apparatus even after the ice pop is removed for consumption. As such, it is necessary to clean the apparatus after each use if the user does not wish to contaminate a second batch of ice pops with the residue of an earlier batch. However, cleaning and washing the apparatus raises the temperature of the apparatus so that the ice pop maker is not, at least temporarily, suitable for its intended purpose. The ice pop maker would have to be returned to a freezer for an extended period thereby defeating the “on demand” operation expected in a quick pop maker. In other words, there is at least a need for an apparatus that has the ability to make consecutive batches of uncontaminated ice pops in an expedited manner. An ice pop maker that would allow an ice pop to be removed in the absence of an extraction tool or release coating would also be desired. 
         [0006]    An ice pop maker in accordance with the following disclosure addresses these and/or other shortcomings of conventional quick ice pop makers and otherwise overcomes the disadvantages presented by existing technologies. 
       SUMMARY 
       [0007]    The present disclosure is directed to an ice pop maker and method of operating the same wherein a selectively removable ice pop mold insert is employed. For the purposes of this disclosure, an ice pop is a frozen comestible on a stick. The subject ice pop maker makes it surprisingly easy to remove the ice pop from the ice pop maker. A hidden release mechanism may also be employed to facilitate the release of an ice pop mold insert from the ice pop maker apparatus. 
         [0008]    The ice pop maker, in accordance with one embodiment of the disclosure, comprises an outer shell, an inner sleeve, refrigerant media, an ice pop stick, a combination stick holder and fluid funnel, and a selectively removable ice pop mold insert. The refrigerant media is stored between the outer shell and inner sleeve. The refrigerant media would typically be some product that freezes below 32 degrees Fahrenheit, such as salt water, propylene glycol, ammonia solution, or the like, although many other fluids could be employed. The refrigerant solution stores sufficient energy to freeze a fluid product placed in the ice pop maker via the mold insert within a matter of minutes. The refrigerant solution is cooled by storing the apparatus in a refrigerated space, such as a freezer, for a period of time. 
         [0009]    In one embodiment, the inner sleeve may employ cooling fins that extend from the inner sleeve into the refrigerant media as a heat exchanger. The increased surface area aids the energy transfer between the refrigerant media to the inner sleeve, as further explained below. In at least one of the embodiments, the inner sleeve has one or more apertures extending all the way therethrough. The removable mold insert can be supported in each of the apertures. 
         [0010]    The independent, selectively removable ice pop mold insert is sized to fit and nest within the inner sleeve so that the outer walls of the mold insert are in close contact with the walls forming the apertures through the inner sleeve. The ice pop stick is placed in the mold insert and can be held in place by the combination ice pop stick holder and fluid funnel. The mold insert is filled with an edible liquid product either before or after the mold insert is placed in the inner sleeve of the ice pop maker. 
         [0011]    The refrigerant media creates a thermal transfer through the inner sleeve and mold insert. When the refrigerant media is properly conditioned, the contents of the mold insert freeze on the ice pop stick in a matter of minutes. Depending on many variables including the starting temperature of the fluid in the mold insert, the storage temperature and length of time the ice pop maker was chilled, and the like, the mold insert contents will generally freeze in about 7 to 15 minutes. Generally, the comestible fluid or mixture freezes in 10 minutes or less. The ice pop (i.e., the frozen material and the stick) is then removed from the mold insert in order to consume the frozen comestible product. 
         [0012]    If the product is sufficiently frozen, the ice pop will not automatically separate from the mold insert. Instead, the user can grasp the mold insert to pull the insert with the ice pop in it from the ice pop maker. It is possible that the mold insert can be frozen or bonded to the sleeve or otherwise hard to grasp. A hidden release mechanism, as discussed further below, can be employed to cause a relative motion between the ice pop maker inner sleeve and the mold insert. The relative motion force is sufficient to release the mold insert from the inner sleeve and to extend a portion of the mold insert above the inner sleeve so that the user can grasp and easily remove the mold insert via the ice pop stick or by grasping and pulling the mold insert. 
         [0013]    Once the mold insert is removed from the apparatus, the ice pop can be released from the mold insert by subjecting the mold insert to ambient air conditions or, more efficiently, by exposing the exterior surface of the mold insert to a fluid bath or stream. This releases the bond between the ice pop and the inner surface of the mold insert so that the ice pop is easily extracted from the mold insert by hand. A user simply grasps the ice pop stick and retracts it from the mold insert. No extraction tool is needed to remove the ice pop from the mold insert, which simplifies the method of operating the apparatus and lowers costs. A release coating on the mold insert is also not needed, further lowering costs. The composition, texture, etc. of the interior surface of the mold insert is not critical as the temperature differential between the inner surface and outer surface can be used to release the ice pop. 
         [0014]    The construction and operation of the subject quick pop maker eliminates any concerns about the ice pop sticking, breaking, or otherwise being damaged in the quick pop maker when trying to remove it via an extraction tool. The subject construction provides a simpler, more cost effective solution to the known problem of removing an ice pop from a quick ice pop maker. 
         [0015]    The construction of the inner sleeve, which has an aperture entirely therethrough (i.e., open at both ends), requires two seals with the outer shell. The first seal is located proximate the top end of the ice pop maker. A second seal adjacent the lower edges or bottom end of outer shell and inner sleeve to contain the refrigerant media inside the cavity formed by the inner sleeve and outer shell. Manufacturing tolerances require the careful arrangement and selection of seals. In one embodiment, a flat seal is employed at the top end and a radial seal is used adjacent the connection at the bottom end. 
         [0016]    An additional problem is presented by maximizing the surface-to-surface contact between the inner sleeve and mold insert. Any gap between the two surfaces acts as an insulator or decreases thermal conductivity between the two parts. Maximum surface contact is desired for heat transfer purposes. In one embodiment, the inner sleeve is to a final shape and the mold insert is created via spin forming and then lathe finished to a final shape. Tolerances between the two parts can be problematic, but deep drawing or other manufacturing methods could be employed. 
         [0017]    As briefly noted above, a hidden release mechanism for the mold insert can be employed. To accomplish one embodiment of the release mechanism, the housing and an inner sleeve are supported upon a base but are spaced apart from the base via post-supported springs. The springs bias the inner sleeve and outer shell away from the base. Downward force on the outer shell or inner sleeve overcomes the spring bias. The inner sleeve and outer shell have a downward range of motion towards the apparatus&#39; base. The mold insert, however, is supported on an upward projecting member of the base or otherwise have a more limited range of downward motion. The upward projecting members are axially aligned with the aperture in the inner sleeve and limit the downward motion of the mold insert. In other words, the upward projecting members act as a “stop” and do allow the mold insert to move downwards to the same extent that the inner shell can move. 
         [0018]    Since the mold insert has a more limited range of motion, or none at all, the downward force on the outer shell causes relative movement between the inner sleeve and the mold insert. As a result, surface tension or bonding between the mold insert and inner sleeve that might impede the removal of the mold insert from the inner sleeve is overcome. A portion of the mold insert is also exposed. A user can then easily remove the mold insert from the ice pop maker apparatus by pulling the ice pop stick or directly grasping and retracting the mold insert. 
         [0019]    An ice pop maker in accordance with the present disclosure is easy to operate and clean and is relatively inexpensive to make and own. The ice pop maker does not require an extraction tool or any specialized release coatings. Moreover, the maker is more sanitary than known ice pop makers in that the portion of the apparatus that contacts the edible material (i.e., the mold insert) is independently removable. Any remnants of the edible material can easily be cleaned from the mold insert without having to wash the inner sleeve or outer shell that house the refrigerant media. As such, cleaning the mold inserts does not dissipate the energy stored in the refrigerant solution as it would if one were required to wash the reside directly off the apparatus itself. Overall, the subject ice pop maker is relatively easy to clean, is more sanitary, is easier to operate, and should cost less to manufacture than known ice pop makers. 
         [0020]    Further features and advantages of the present invention will become apparent to those of skill in the art from the following detailed description of a preferred embodiment taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]      FIG. 1  depicts one embodiment of the subject ice pop making apparatus with removable mold insert as disclosed herein; 
           [0022]      FIG. 2  is a top view thereof; 
           [0023]      FIG. 3  is an exploded view thereof; 
           [0024]      FIG. 4  is an exploded, side, cross-sectional view thereof; 
           [0025]      FIG. 5A  is a cross-sectional view from one end of the apparatus as disclosed herein; 
           [0026]      FIG. 5B  is an additional cross-section side view thereof; 
           [0027]      FIG. 6  is a close up cross-sectional view thereof; and 
           [0028]      FIG. 7  is a perspective view from the bottom and one end of the subject apparatus as disclosed herein. 
       
    
    
     DETAILED DESCRIPTION 
       [0029]    The present disclosure is directed to an ice pop maker and the method of using the same. The ice pop maker is described in terms of various embodiments disclosed and illustrated herein. The subject ice pop maker comprises a novel construction and method of operation. The ice pop maker includes various components including a selectively removable ice pop mold insert that provides for a more sanitary apparatus with easier operation than known devices. A release mechanism can facilitate the removal of the mold insert. The subject apparatus will freeze a comestible fluid or mixture in a very short period of time, typically in 10 minutes or less. Of course, the present invention is not limited to the specific embodiments as follows but also includes variations and equivalent structures that would be apparent to one of skill in the art upon review of the disclosure as a whole. 
         [0030]    As illustrated herein, and with specific reference to  FIGS. 1 and 2 , the quick pop making apparatus  10  comprises, in at least one embodiment, an outer shell  12  and an inner sleeve  14  that are joined together to create a sealed cavity therebetween. A refrigerant media (not illustrated) is stored between outer shell  12  and inner sleeve  14  in the cavity. The refrigerant media would typically be some product that freezes below 32 degrees Fahrenheit, such as salt water, propylene glycol, ammonia solution, or the like, although many other fluids could be employed. Ice pop maker  10  is stored in a freezer for a period of time to lower the temperature of the refrigerant media. This thermal energy is stored in the refrigerant media for a period of time when ice pop maker  10  is removed from the freezer. 
         [0031]    Outer shell  12  can be plastic, metal, or any suitable fluid-tight material. Outer shell  12  forms the outer and lower walls of the refrigerant media cavity. For cost savings and to prevent energy loss of the refrigerant media though outer shell  12 , a plastic shell is preferred but not required. A bezel  13  is snap-fit or otherwise secured to the upper edge of shell  12 . Bezel  13  can be formed from plastic or other suitable material, although it is thought a material with low thermal conductivity is preferred so as to protect a user from a cold surface. To that end, bezel  13  can further include handles  15  to facilitate handling and operation of ice pop maker  10 . 
         [0032]    Outer shell  12  is fastened to inner sleeve  14  by screws or other known fasteners or fastening mechanism. Inner sleeve  14  forms the upper wall of the refrigerant media cavity as well as at least one passageway therethrough. 
         [0033]    For reasons elaborated on below, inner sleeve  14  is preferably a material with a relatively high rate of thermal conductivity, such as a metal. A plurality of cooling fins  17  (see, in particular,  FIG. 5A-6 ) extends from inner sleeve  14  into the refrigerant media cavity created by inner sleeve  14  and outer shell  12 . Cooling fins  17  also exhibit a high rate of thermal conductivity and are submerged in the refrigerant media. Fins  17  provide a greater surface area of contact between inner sleeve  14  and the refrigerant media. 
         [0034]    Referencing also  FIGS. 3 and 4 , and as briefly noted above, inner sleeve  14  comprises at least one aperture  16  extending therethrough from an upper end of inner sleeve  14  to a bottom end of inner sleeve  14 . The upper end of aperture  16  is chamfered outwardly. Sleeve  14  may be mechanically stamped, deep-drawn, die-cast or produced by other suitable means. A die-cast aluminum construction is preferred but not required. 
         [0035]    An independent and selectively removable mold insert  18  can be inserted into inner sleeve  14  via aperture  16 . Mold insert  18  is sized to nest within inner sleeve  14  and includes a first open end and a second closed end. While mold insert  18  is illustrated herein as having a circular cross section and a tapered body from the open end to the closed end, which corresponds to the shape of aperture  16 , the specific shapes of aperture  16  and mold insert  18  are not critical. For the most efficient operation of ice pop maker  10 , the outer dimensions of mold insert  18  should closely conform to the dimensions of aperture  16  so as to maximize the surface contact between the two. Mold insert  18  can rest on the chamfered portion of aperture  16  (i.e., it is suspended within aperture  16 ) or stand on or be supported by an optional base projection  40  adjacent the lower end of aperture  16 . 
         [0036]    An upper seal  20  is placed between inner sleeve  14  and outer shell  12  to hold the two components together more securely and to prevent the escape of any refrigerant media from the cavity. Upper seal  20  can be a known gasket or seal, such as a flat seal. Aperture  16  through inner sleeve  14  requires there be an additional seal at the lower end of inner sleeve  14 . It has been found that a radial seal  22  effectively joins the bottom end of inner sleeve  14  to outer shell  12  and also prevents the escape of the refrigerant media from the cavity created by outer shell  12  and inner sleeve  14 . Other types of seals or gaskets may be suitable for lower seal  22 . 
         [0037]    Mold insert  18  can be filled with an edible liquid material before or after being inserted into aperture  16  of inner sleeve  14 . A funnel  24  can nest in the upper opening of mold insert  18  to guide a fluid into mold insert  18 . Funnel  24  includes an opening therethrough and a tapered cross-sectional shape. A bridge  26  extends across the funnel opening and includes a stick opening. An ice pop stick  28  is supported in the stick opening to retain stick  28  in position in mold insert  18 . The stick opening can accommodate molded plastic sticks, conventional wooden ice pop sticks (i.e., Popsicle™ sticks), and the like. 
         [0038]    The chilled refrigerant media extracts thermal energy from the fluid or mixture in mold insert  18  through inner sleeve  14  and mold insert  18 . The media has enough stored energy to freeze the fluid or mixture on stick  28  to form an ice pop. Mold insert  18  may be plastic, metal or other viable material. A metal mold insert  18  is thought to effectively allow the rapid transfer of thermal energy between the refrigerant media and the interior of the removable mold insert  18 . In addition, in the event mold insert  18  is removed from the apparatus while containing an ice pop, exposing a metal mold insert  18  to a warm environment (e.g., running tap water, warm air, or the like) will quickly cause the frozen material in mold insert  18  to loosen from mold insert  18  due to the effective heat transfer provided by metal and, in part, due to the expansion and contraction of the metal. In any event, no extraction tool is required to remove the resulting ice pop. A release coating is also not needed. The independent, selectively removable mold insert  18  provides for the easy operation of ice pop maker  10 , easy cleaning of the same, and facilitates the removal of the ice pop from ice pop maker  10 . 
         [0039]    By this removable mold insert construction, the liquid or material used to create the ice pop does not touch inner sleeve  14 . Consequently, inner sleeve  14  is not contaminated with foodstuff at any point. In fact, inner sleeve  14  cannot independently retain any fluid introduced via aperture  16  as inner aperture  16  is open on both ends of inner sleeve  14 . In other words, inner sleeve  14  cannot act as a reservoir. 
         [0040]    Stick  28  is envisioned as a one-piece, injection-molded plastic stick, which would be reusable and machine washable. Funnel  24  can be independent of stick  28  so that it is operable with a variety of different stick types including traditional, wooden ice pop sticks. Funnel  24  could alternatively be a molded collar proximate to and integral with one end of stick  28 . 
         [0041]    Overall, the removal of the ice pop from ice pop maker  10  is facilitated by the use of a removable mold insert  18 . While the thermal exchange between the refrigerant media and fluid or mixture to be frozen occurs through two intervening layers (i.e., the wall of inner sleeve  14  and mold insert  18 ), it was surprisingly found that the rapid freezing of the edible product could be achieved. Removing the ice pop and mold insert  18  from ice pop maker  10  aided the cleaning of the ice pop making apparatus  10  and made it possible to produce consecutive batches of ice pops without any cross-contamination issues. 
         [0042]    A removable mold insert, as disclosed herein, produces a method of using the subject apparatus that is unique to quick ice pop makers. To operate the ice pop maker  10 , a user would place ice pop maker in a freezer for an amount of time sufficient to chill and condition the refrigerant solution. The apparatus is removed from the freezer. Ice pop mold insert  18 , with or without any contents, is placed in the upper end of aperture  16  of inner sleeve  14 . The combination funnel and stick holder  24  and ice pop stick  28  are placed in ice pop mold insert  18 . Unless already completed, a fluid or mixture is added to ice pop mold insert  18 . Advantageously, the fluid can be added to mold insert  18  prior to mold insert  18  being placed in quick pop maker  10  so that any spills do not contaminate or freeze to ice pop maker  10 . 
         [0043]    In a period of minutes, the fluid or mixture in mold insert  18  will be frozen to stick  28 . A user can grasp mold insert  18  and remove mold insert  18  from ice pop maker  10 . The exposure to ambient air conditions or a bath or stream of fluid will release the ice pop from mold insert  18 . If a second or subsequent ice pops are desired, a user can clean mold insert  18 , dry it off, and reinsert mold insert  18  for further use. Cross contamination between ice pop batches is prevented and it is not necessary or suggested to clean outer shell  12  or inner sleeve  14  between batches, which would dissipate the energy stored in the refrigerant media. 
         [0044]    It is possible for mold insert  18  to create sufficient surface bonding or otherwise freeze to inner sleeve  14  such that an optional mold insert release mechanism might be employed. In one embodiment, the mold insert release mechanism comprises a relative motion system between inner sleeve  14  and mold insert  18 . 
         [0045]    In further detail, and with reference to the figures, including  FIGS. 4-7 , outer shell  12  and inner sleeve  14  are supported upon a base  38  but spaced apart from base  38  via post-supported springs  39 . Springs  39  bias inner sleeve  14  and outer shell  12  away from base  38 . Downward force on outer shell  12  or inner sleeve  14  overcomes the spring bias thereby allowing inner sleeve  14  and outer shell  12  a range of downward motion. Mold insert  18 , however, is either suspended in aperture  16  of sleeve  14  or is supported by base  38  in a manner that does not permit the same, or any, range of downward motion. Therefore, the downward movement of outer shell  12  and inner sleeve  14  causes relative movement between inner sleeve  14  and mold insert  18 . As a result, surface tension, bonding or any other binding force that might impede the removal of mold insert  18  from inner sleeve  14  is overcome. In addition, the downward movement of inner sleeve  14  relative to mold insert  18  can physically present or expose mold insert  18  above the top wall of inner sleeve  14  so that mold insert  18  can be more easily grasped by a user. The user then easily removes mold insert  18  from ice pop maker  10 . The ice pop is released from mold insert  18  in the manner described above. 
         [0046]    In still further detail, as perhaps best illustrated in the close-up, sectional illustration of  FIG. 6 , outer shell  12  includes a circumferential lower lip  50  that fits within a groove  52  provided by base  38 . A plurality of posts  54  extend down from the bottom side of outer shell  12 . Posts  54  are received by pockets  56  of base  38  and extend through apertures in the pockets. Fasteners are attached to the distal end of posts  54 . The fasteners do not fit through the pocket openings so that outer shell  12  and inner sleeve  14  are secured to base  38 . Posts  54  can move down through the pocket apertures. However, posts  54  are naturally biased to the uppermost position by the bias force of springs  39  on outer shell  12 . The post fasteners limit the upward range of motion. 
         [0047]    Springs  39  can comprise coil or other suitable types of springs that are situated around some or all of posts  54 . Springs  39  bias shell  12  and sleeve  14  away from base  38 . As a result, the fasteners are brought into contact with base  38 . In this position, lip  50  is positioned in groove  52  but there is downward range of motion. A user pushes down on outer shell  12  or inner sleeve  14 . The spring bias is defeated and posts  54  move down through the pocket apertures. Lip  50  also moves down within groove  52  until it abuts base  38 . 
         [0048]    Base  38  further includes upwardly extending base projections  40  that limit the downward motion of mold insert  18  relative to inner sleeve  14 . Mold insert  18  is either in contact with projections  40  at all times or are suspended in aperture  16  just above base projections  40 . Therefore, mold inserts  18  have little to no downward range of motion and specifically less of a downward range of motion relative to the base than do the outer shell  12  and/or inner sleeve  14 . Therefore, pushing down on outer shell  12  ‘releases’ mold insert  18  from inner sleeve  14 . A user grasps and removes mold insert  18  from ice pop maker  10 . 
         [0049]    While the present disclosure has been described with reference to specific embodiments thereof, it will be understood that numerous variations, modifications and additional embodiments are possible, and all such variations, modifications, and embodiments are to be regarded as being within the spirit and scope of the invention.