Abstract:
A blade assembly suited for both blending and food processing in small throat blender jars is provided. The blade assembly comprises a plurality of blade forms each designed to perform a specific blending or processing task while simultaneously working together and with the geometric restrictions of the jar to optimize the assembly&#39;s capability to crush ice, blend or mix liquids and/or semi-solid materials, and to chop, cut, or slice solid food items without the need for user interaction to clear compacted items from the blades and/or the walls or bottom of the jar during its operation. The improved performance also serves the beneficial side effect of improved bearing and motor life in the blender/food processor.

Description:
FIELD OF THE INVENTION 
       [0001]    The present disclosure generally relates to a blade assembly for use in a kitchen appliance. In particular, the present disclosure is directed to a blade assembly suited for blending, food processing, and crushing ice. More particularly, the present disclosure is directed to a blade assembly for blending, food processing, and crushing ice in small throated blender jars. 
       BACKGROUND OF THE INVENTION 
       [0002]    The statements of this section merely provide background information related to the present disclosure and may not constitute prior art. 
         [0003]    Blenders are household devices often used to blend or mix drinks or liquids. Food processors are household devices used to chop, cut, slice, and/or mix various solid foods such as vegetables, fruits, or meats. Different blade designs and rotational speeds are used in blenders and food processors in order to accomplish the mixing or cutting actions desired. 
         [0004]    Typically, the blade attachment in conventional blenders consists of two generally U-shaped blades, a top blade and a bottom blade, joined together at a central point with their respective ends oriented in opposite directions. Because of the blender blade design, conventional blenders usually are not able to chop, slice, or cut solid foods because solid food does not flow into the U-shaped blades without the addition of a liquid. Although the solid food may make some contact with the blades, typically at least some liquid must be added in order to liquefy or cut the solid food into very small pieces. Without some liquid, blenders tend to pulverize solid foodstuffs. 
         [0005]    Similarly, typical food processing blade arrangements are designed to generate small pieces of foodstuffs not to liquefy or mix. Even when run for long periods the geometry of typical food processing blades fails to liquefy foodstuffs due to their inability to circulate the food within the jar and to continually rotate the processed foods back through the blades to process it into ever finer sizes. 
         [0006]    In an aspect, the present disclosure is directed to a blade arrangement suited for providing the mixing and liquefying capabilities of typical blender blade arrangements and the ice crushing, chopping, cutting, and slicing capabilities of the a food processor blade arrangement. In an aspect, the disclosure is directed to such a multi-function blade arrangement for use in small-throat blender jars. 
       SUMMARY OF THE INVENTION 
       [0007]    In accordance with the present disclosure a blade assembly for use in a small throat blender jar and having both blending/mixing, as well as enhanced food processing capabilities is disclosed. The blade assembly may comprise a base member having a central hollow post. Mounted with the post may be a rotating shaft which is connected to the appliance&#39;s motor at one end and the blade assembly at the other. The motor drives the rotating shaft which in turn moves the blade assembly causing the blending/processing of the liquid and/or food items within the blender jar. 
         [0008]    The blade assembly is optimally designed to provide improved blending and mixing capabilities, as well as enhanced food processing operations. The assembly may comprise a plurality of blades in a stacked formation that operate in concert with each other to individually and cooperative achieve the desired handling of the items within the jar. In one embodiment of the present invention, the blade assembly may include a first or top blade form, a second or middle blade form, and a third or middle blade form joined together to form a blade stack. 
         [0009]    The first or top blade form may be a generally U-shaped blade primarily useful for crushing ice. The top blade form may comprise a central, generally flat base portion extending radially outward with respect to the axis of rotation of the blade assembly. First and second wing portions may extend at an angle upward from opposing ends of the central base of the top blade form. It should be noted that the angle of each wing portion may be individually set to optimize the blade&#39;s performance individually and in conjunction with the remainder of the blade assembly and the internal jar geometry. 
         [0010]    The third or bottom blade form may similarly be a U-shaped blade primarily intended for liquefying material and also for clearing the bottom of the jar to enhance the blade assembly&#39;s interaction with the jar contents. Combined with the top blade form, the opposing U-shaped blades (the top blade form opening upward and the bottom blade form opening downward) serve to function as typical blender/mixer blades. The bottom blade form may comprise a central, generally flat base portion extending radially outward with respect to the axis of rotation of the blade assembly. First and second curved wing portions may extend at an angle downward and outward from opposing ends of the central base of the bottom blade form. It should be noted that the angles of the curved wing portions of the bottom blade form are essentially identical so as to ensure an optimal clearing function of the lower portion of the jar without the introduction of any blade cavitation or turbulent flow that would unnecessarily pull the jar&#39;s contents back beneath the blade stack before its complete processing. 
         [0011]    Finally, the second or middle blade form of the blade stack may comprise a central, generally flat base extending radially outward with respect to the axis of rotation of the blade assembly. As with the top blade form, a first and second wing portion may extend at an angle upward from opposing ends of the central base. The middle blade form, however, may be generally S-shaped before being bent to create the first and second wing portions. As such, first and second wing portions may also curve circumferentially away from the central base. Such a shape provides for a longer blade length which may have a continuous-radius edge. While bent into a generally U-shape, the continuous-radius edge allows the folded middle blade form to operate as effectively as typical flat food processing blades at chopping, cutting, and slicing solid food items, including vegetables, nuts, and meats. 
         [0012]    Optimized blade geometries, as well as a blade stack layout that ensures limited, if any, interference by one blade form with the performance of another blade form ensures the blade assembly is suited for providing blending/mixing capabilities, while additionally providing enhanced food processing and ice crushing performance. All of the performance enhancements additionally serve to reduce wear-and-tear on the assembly&#39;s bearings and the appliance&#39;s motor. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    The organization and manner of the structure and function of the present invention, together with further aspects and advantages thereof, may be understood by reference to the following description taken in connection with the accompanying drawings, wherein like reference numerals identify like elements, corresponding part and/or features and in which: 
           [0014]      FIG. 1  shows a perspective view of a blade assembly in accordance with a preferred embodiment of the present disclosure; 
           [0015]      FIG. 2  shows an exploded view of the blade assembly of  FIG. 1   
           [0016]      FIG. 3  shows a top view of the blade assembly of  FIG. 1 ; 
           [0017]      FIG. 4A  shows a top view of the blade stack of the blade assembly of  FIG. 1 ; 
           [0018]      FIG. 4B  shows a side view of the blade stack of  FIG. 3A ; 
           [0019]      FIG. 4C  shows an exploded view of the blade stack of  FIG. 3A ; and 
           [0020]      FIG. 4D  shows a composite side and top view of the middle blade form of the blade stack of  FIG. 4A  and indicating blade angles relative to the horizontal and center line of the blade form; 
           [0021]      FIG. 5  shows a top view of the blade stack of  FIG. 4A  and indicating relative blade orientations; 
           [0022]      FIG. 6  shows a cross-section view of the blade assembly of  FIG. 1  mounted in small throat jar in a combination blender/food processor. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0023]    While the present invention may be susceptible to embodiment in different forms, there are shown in the drawings, and herein will be described in detail, embodiments with the understanding that the present description is to be considered an exemplification of the principles of the invention and is not intended to limit the invention to that as illustrated and described herein. Instead, it is envisioned that those skilled in the art may devise various modifications and equivalents without departing from the spirit and scope of the appended claims. 
         [0024]    Referring now to  FIGS. 1-3 , a blade assembly  100  in accordance with the present disclosure is shown. Blade assembly  100  comprises a base  102  having a generally circular shape with an extended central hollow post  104 . A collared rotational shaft  106  is mounted to and driven by the blender/food processor motor (not shown) at a first end. Rotational shaft  106  passes through the hollow post  104  and is removably affixed to a blade stack  200  at a second end. A sealing gasket  108  is provided about the outer periphery  110  of base  102  for sealing the blender/food processor jar  112  against the base  102  during operation. 
         [0025]    Blade stack  200  is designed to allow for traditional blending functions while simultaneously providing improved food processing capabilities without the need to remove, change or alter the blade assembly  100  within the blender/food processor appliance. Blade stack  200 , as shown in an exemplary embodiment in  FIGS. 4A-4C , includes a top or first blade form  210 , a middle or second blade form  220 , and a third or bottom blade form  230 . The blade forms  210 ,  220 , and  230  may be made of any durable material such as metal, steel, carbon, composites, or any combinations of such material which can be sharpened and withstand the high stresses and heats generated in this environment. 
         [0026]    The top blade form  210  and bottom blade form  230  are preferably similar to a conventional blender blade design (one or more generally U-shaped blades). In particular, the top blade form  210  includes a central, substantially flat base  212  that extends radially with respect to the rotational axis R-R of the blade assembly. A first wing portion  214  extends at a first angle upward from the base  212  and a second wing portion  216  extends at a second angle upward from an opposing end of the base  212 . While it is preferred that first and second wing portion&#39;s respective angles are not equal so as to provide enhanced blending and processing, it should be noted that such angles may be identical. 
         [0027]    As with the top blade form  210 , bottom blade form  230  includes a central, substantially flat base  232  extending radially with respect to the rotational axis R-R of the blade assembly  100 . First  234  and second  236  curved blades are preferably formed integrally with the base  232 , and extend downward and outward from opposing ends of the base  232 . The curved shape of the blades  234  and  236  enhances blending and processing, and permits the edges of the blades  234  and  236  to extend to adjacent the blade assembly base  102 . In this manner, blended and processed items are dislodged and forced upward from the bottom of the jar  112 . 
         [0028]    The middle blade form  220  is an altered food processing blade design suited for use in a small throat jar  112 . Wherein a typical food processor blade arrangement may include one or more generally flat blades extending radially outward from a central point of rotation, the middle blade form  220 , in accordance with a preferred embodiment, is an S-shaped blade bent at opposing ends to a generally U-shaped configuration. The middle blade form  220  cooperates with the top and bottom blade forms  210  and  230  to enhance the circulation of blended or processed items while avoiding interference with the performance of the other blades. 
         [0029]    Middle blade form  220  has a central, substantially flat base  222  extending radially from the axis of rotation R-R of the blade assembly  100 . The central base  212 ,  222 , and  232  of each of the top, middle and bottom blade forms  210 ,  220 , and  230  are circumferentially offset from each other by a predefined angle as will be discussed in greater detail below. A first wing portion  224  extends upward and curves circumferentially away from the middle blade form&#39;s central base  222 . Similarly, from an opposing end of the central base  222 , a second wing portion  226  extends upward and curves circumferentially away from the central base  222 . The resultant compound curve of the first and second wing portions  224  and  226  of the middle blade form  220  allow for a longer blade length for improved food processing capabilities. 
         [0030]    The longer blade lengths allowed by the compound curve shape of the middle blade form  220  provides a continuous-radius edge along the entirety of each of the wing portions  224  and  226  so as to improve food processing performance of the blade assembly  100  similar to that of the typical flat blades found in food processors. A knife-sharpened edge additionally enhances the middle blade form&#39;s performance. Still further, the gull wing shape of the middle blade form  220  allows for its use in a small throat blender/processor jar  112  without negatively effecting the circulation of the blended/processed items during its operation. In part, the gull wing shape of the middle blade form  220  achieves this balance of improved performance and reduced circulatory impact by remaining an optimal distance from the throat wall  114  of the blender/processor jar  112 . The gull-wing shape allows for a balancing of being far enough away from the wall  114  so as not to merely force items down into the bottom blade form  230  and thus liquefy them, while not placing the blade tips so far from the throat wall  114  as to fail to pull the processed items into the blade stack  200  for processing. As a result, the enhanced performance of the blade stack  200 , and the assembly  100  as a whole, are directly related to the defined angles involved in shaping the middle blade form  220 . 
         [0031]    The enhanced processing performance is also a direct result of the middle blade form&#39;s orientation to the top and bottom blade forms  210  and  230  as best seen in  FIG. 4D . More specifically, it is preferred that the wing portions  224  and  226  of the middle blade form  220  make generally about a 75° angle with the horizontal plane (i.e., generally about a 105° vertical angle between the wing portions  224  and  226  and the central base  222  of the middle blade form  220 ). Further, the point of intersection of the wing portions  224  and  226  and the central base  222  of the middle blade form  220 , the bend line, makes an angle generally about 34.5° with the center line of the S-shaped middle blade form&#39;s central base  222 . These precise angles provide for improved interaction between the middle blade form  220 , the jar wall  114 , and the processed items (not shown). 
         [0032]    With regard to the interaction of the top, bottom and middle blade forms  210 ,  220 , and  230 ,  FIG. 5  best shows their respective orientation to one another. The blade tips of the blending blades, the top and bottom blade forms  210  and  230 , are offset by an angle generally about 27.7° and the angle formed between the tips of the middle and bottom blade forms  220  and  230  is generally about 77°. It is these angles of rotation and the various angles of lift on the individual wing portions of the various blade forms that directly drive the performance of the blade assembly  100  by reducing interference by one blade form with another while enhancing the ability to circulate the blended/processed items and reducing the wear-and-tear on the assembly&#39;s bearings and the blender/processor motor (not shown). 
         [0033]    In use, the blade assembly  100 , in accordance with the preferred embodiment, is mounted within a blender/food processor appliance base  116  having a motor suited for driving the blade assembly  100 . The blender jar  112  is mounted over the blade assembly  100  and within the appliance base  116 . The sealing gasket  108  located between the blade assembly base  102  and the bottom  118  of the jar  112  serves to make the combined structure water tight. 
         [0034]    Upon the introduction of items into the jar  112  to be blended/processed, a user may initiate the operation of the appliance. The top blade form  210  serves to effectively crush ice. The middle blade form  220  with its long continuous radius edge blade operates to process solid food stuffs including heavier items such as nuts, vegetables, and meats. Finally, the bottom blade form  230  operates to assist in the mixing of larger particulate matter and liquids by enhancing circulation of the items being blended/processed and to liquefy soft food items, such as tomatoes. 
         [0035]    The circulation of the items within the blending jar  112  are based on a complex combination of the fluid dynamics of the blades forms  210 ,  220 , and  230  and the interior shape of the jar  112 . In order to introduce additional mixing of the contents of the jar  112 , at roughly equal spacing about the interior of the jar  112  are provided rib structures  119  that introduce a interference in the rotational flow stream of the contents during operation of the appliance. Further, the blade form geometries themselves serve to introduce lifting forces to the jar&#39;s contents. Instead the blades are designed to avoid cavitation which may serve to reduce the effectiveness of the blade assembly  100 , as well as decrease bearing and motor life in the appliance. 
         [0036]    Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification and the following claims.