Food processor with adjustable blade assembly

A food processor includes a bowl with a removable lid. Food items are advanced into the bowl through a feed tube formed in the lid where they are cut by a blade assembly. A rotating disk is adjustable relative to the blade assembly to vary the thickness of the food items cut by the blade assembly.

FIELD OF THE INVENTION

The present disclosure relates generally to a domestic food processor, and more particularly to a food processor having a control for adjusting the cutting thickness of the food processor.

BACKGROUND OF THE INVENTION

A food processor is a motorized domestic appliance for manipulating (e.g., chopping, slicing, dicing, shredding, grating, or blending) food items. Such an appliance includes a bowl with a removable lid. Food items are inserted into the bowl through a feed tube formed in the lid where they are cut by motor-driven cutting tool.

Food processors typically come equipped with a number of interchangeable cutting tools for slicing, shredding, or other food processing operations. One common cutting tool is a rotating disk-type cutter. Such a cutting tool includes a rotating disk having a cutting blade fixed thereto. The cutting blade is secured to the rotating disk at a location adjacent to an aperture formed in the disk so that pieces of food cut by the blade fall through the aperture and collect in the bottom of the bowl.

SUMMARY OF THE INVENTION

According to one aspect of this disclosure, a food processor includes a base having a motor positioned therein, a removable bowl coupled to the base, and a removable lid coupled to the bowl. The lid has a feed tube that opens into the bowl. A cutting blade is positioned in the bowl and driven by the motor to cut food items advanced through the feed tube. The food processor also includes a rotating disk upwardly and downwardly movable relative to the cutting blade to adjust the distance therebetween, and a user-operated pin positioned below the rotating disk. The user-operated pin is movable between a first position in which the rotating disk is prevented from moving upwardly and downwardly relative to the cutting blade, and a second position in which the rotating disk is permitted to move upwardly and downwardly relative to the cutting blade. In some embodiments, the rotating disk may include a sleeve extending downwardly from a lower surface thereof, and the cutting blade may be coupled to a central shaft positioned in the sleeve of the rotating disk.

In some embodiments, the user-operated pin may include a pin body extending from a first end through a sidewall of the sleeve to a second end received in an aperture formed in the central shaft. In some embodiments, the sidewall of the sleeve may include a first plurality of teeth, an outer surface of the pin body may have a second plurality of teeth extending therefrom, and a number of the first plurality of teeth may be engaged with the second plurality of teeth when the user-operated pin is in the first position.

Additionally, in some embodiments, the first plurality of teeth may be spaced apart from the second plurality of teeth when the user-operated pin is moved to the second position. In some embodiments, the food processor may also include a spring having a first spring end positioned at a bottom of the aperture of the central shaft and a second spring end coupled to the second end of the user-operated pin. The spring may bias the user-operated pin in the first position. In some embodiments, a guide pin may extend outwardly from the bottom of the aperture, and the spring may extend over the guide pin.

In some embodiments, the food processor may also include a lever pivotably coupled to a sidewall of the sleeve and may have a first lever end contacting the second end of the user-operated pin. Movement of the user-operated pin between the first position and the second position may cause the lever to pivot about an axis between a first lever position and a second lever position. In some embodiments, the lever may extend from the first lever end to a second lever end. The second lever end may be coupled with the central shaft when the lever is at the first lever position. In some embodiments, the central shaft may have an outer surface with a plurality of teeth extending therefrom, and the second lever end may be engaged with a number of the plurality of teeth when the lever is at the first lever position, thereby preventing the rotating disk from moving relative to the cutting blade.

In some embodiments, the second lever end may be spaced apart from the plurality of teeth at the second lever position, thereby permitting movement of the rotating disk relative to the cutting blade. In some embodiments, the food processor may also include a spring having a first end coupled to a sidewall of the sleeve and a second end coupled to the second lever end. The spring may bias the lever in the first lever position, thereby maintaining the user-operated pin in the first position and preventing movement of the rotating disk relative to the cutting blade. Additionally, in some embodiments, a button may be secured to a first end of the user-operated pin, and depressing the button moves the user-operated pin from the first position to the second position.

According to another aspect, a food slicer assembly for a food processor is disclosed. The food slicer assembly includes a cutting blade, a rotating disk upwardly and downwardly movable relative to the cutting blade to adjust the distance therebetween, and a locking mechanism positioned below a lower surface of the rotating disk. The locking mechanism includes a user-operated pin that is movable between a first position in which the locking mechanism prevents the rotating disk from moving upwardly and downwardly relative to the cutting blade, and a second position in which the locking mechanism permits the rotating disk to move upwardly and downwardly relative to the cutting blade.

In some embodiments, the food slicer assembly may further include a sleeve extending downwardly from the lower surface of the rotating disk, and a central shaft positioned in the sleeve. The central shaft may have the cutting blade coupled thereto. In some embodiments, the locking mechanism may include a first plurality of teeth extending from a sidewall of the sleeve. The user-operated pin may extend through the sleeve into the central shaft and may have a second plurality of teeth extending therefrom. The second plurality of teeth may be engaged with a number of the first plurality of teeth when the user-operated pin is in the first position and spaced apart from the first plurality of teeth when the user-operated pin is moved to the second position.

In some embodiments, the locking mechanism may include a plurality of teeth extending from the central shaft, and a lever extending from a first end coupled to the user-operated pin to a second end. The second end of the lever may be engaged with a number of the teeth when the user-operated pin is in the first position and spaced apart from the plurality of teeth when the user-operated pin is in the second position. In some embodiments, the lever may be pivotably coupled to the sleeve.

According to another aspect, the food processor includes a base having a motor positioned therein, a removable bowl coupled to the base, a cutting blade positioned in the bowl and secured to a central shaft driven by the motor, and a rotating disk having the central shaft extending therethrough. The rotating disk is upwardly and downwardly movable between a plurality of positions relative to the cutting blade. The food processor also includes a locking mechanism positioned below a lower surface of the rotating disk. The locking mechanism includes a user-operated pin extending through the rotating disk that is movable between a first position in which the rotating disk is prevented from moving upwardly and downwardly relative to the cutting blade, and a second position in which the rotating disk is permitted to move upwardly and downwardly relative to the cutting blade.

In some embodiments, the locking mechanism may include a first plurality of teeth extending from a sidewall of the rotating disk, and the user-operated pin may have a second plurality of teeth extending therefrom. The second plurality of teeth may be engaged with a number of the first plurality of teeth when user-operated pin is in the first position and spaced apart from the first plurality of teeth when the user-operated pin is moved to the second position.

According to another aspect of this disclosure, a food processor includes a base having a motor positioned therein, a removable bowl coupled to the base, and a removable lid coupled to the bowl so as to define a processing chamber. The lid has a feed tube that opens into the bowl. The food processor also includes a blade assembly positioned in the processing chamber and driven by the motor, and the blade assembly has a flange extending therefrom. A rotating disk is movably coupled to the blade assembly, and the rotating disk has a plurality of slots formed therein. Each of the slots is sized to receive the flange of the blade assembly. The rotating disk is movable relative to the blade assembly between a plurality of cutting positions to produce cut food items of varying thicknesses, and the flange of the blade assembly is received into one of the plurality of slots at each of the plurality of cutting positions.

In some embodiments, the rotating disk may include a blade support pivotably coupled to an outer rim of the rotating disk. The plurality of slots may be formed in the blade support. In some embodiments, the blade support may be movable between a first position where the flange of the blade assembly is received in one of the plurality of slots, and a second position where the flange of the blade assembly is spaced apart from each of the plurality of slots. Additionally, in some embodiments, the rotating disk may be prevented from moving relative to the blade assembly when the blade support is placed in the first position, and the rotating disk may be permitted to move relative to the blade assembly when the blade support is placed in the second position.

In some embodiments, the outer rim of the rotating disk may have an opening defined therein, and the blade support may have a body positioned in the opening when the blade support is placed in the first position. The body of the blade support may extend outwardly from the opening when the blade support is placed in the second position.

In some embodiments, the rotating disk may include a locking device configured to maintain the blade support in the first position. In some embodiments, the locking device may include a tab extending from the blade support, and the tab may be received in a recess formed in the outer rim of the rotating disk when the blade support is placed in the first position.

In some embodiments, the plurality of slots may include at least five slots. Additionally, in some embodiments, the blade assembly may include a cutting blade secured to a mounting arm extending from a central shaft. In some embodiments, the flange of the blade assembly received in one of the plurality of slots may be an outer edge of the cutting blade when the rotating disk is placed at a first cutting position, and the flange of the blade assembly received in one of the plurality of slots may be an arcuate lip of the mounting arm when the rotating disk is placed at a second cutting position.

According to another aspect, a food slicer assembly for a food processor is disclosed. The food slicer assembly includes a cutting blade having an outer edge, and a rotating disk movable to a plurality of positions relative to the cutting blade to adjust the distance therebetween. The rotating disk has an outer rim positioned adjacent to the outer edge of the cutting blade, and a blade support coupled to the outer rim, the blade support includes a plurality of slots, each of which is sized to receive the outer edge of the cutting blade. The outer edge of the cutting blade is received in a first slot at a first position of the rotating disk.

In some embodiments, the food slicer assembly may further include a central shaft secured to an inner edge of the cutting blade, and a mounting arm secured to the central shaft and positioned below the cutting blade. In some embodiments, the mounting arm may have an arcuate lip extending parallel to the outer edge of the cutting blade. The lip may be received in the first slot of the blade support at a second position of the rotating disk.

In some embodiments, the blade support may include a body extending from a first end, and the first end may be hinged to the outer rim of the rotating disk such that the blade support is rotatable about a vertical axis. In some embodiments, when the rotating disk is at the first position, the outer edge of the cutting blade may be received in the first slot when the blade support is placed at a first position about the vertical axis, and the outer edge of the cutting blade may be spaced apart from each of the plurality of slots when the blade support is placed at a second position about the vertical axis.

Additionally, the first end of the body of the blade support may be coupled to the outer rim of the rotating disk via a pivot joint. The pivot joint may have the vertical axis extending therethrough.

According to another aspect, a food processor includes a base having a motor positioned therein, a removable bowl coupled to the base, a removable lid coupled to the bowl. The lid has a feed tube that opens into the bowl. A blade assembly is positioned in the bowl and is driven by the motor, and a rotating disk is movable between a plurality of cutting positions relative to the blade assembly. The rotating disk has a blade support that includes a slot corresponding to each of the plurality of cutting positions, each slot being sized to receive a flange of the blade assembly.

In some embodiments, the blade assembly may include a cutting blade having an outer edge. The rotating disk may have an outer rim positioned adjacent to the outer edge of the cutting blade, and the blade support may be pivotably coupled to the outer rim. In some embodiments, the blade support may be pivotable between a first position where the outer edge of the cutting blade is received in one slot of the blade support, and a second position where the outer edge of the cutting blade may be spaced apart from the blade support.

In some embodiments, the flange of the blade assembly received in one of the plurality of slots may be the outer edge of the cutting blade when the rotating disk is placed at a first cutting position.

According to another aspect of the disclosure, a food processing device is disclosed. The food processing device includes a base having a motor positioned therein, a removable bowl coupled to the base, and a removable lid coupled to the bowl so as to define a processing chamber. The lid has a feed tube that opens into the bowl. The food processing device also includes a blade assembly positioned in the processing chamber, which is driven by the motor and includes a cutting blade to cut food items advanced through the feed tube, and a rotating disk upwardly and downwardly movable relative to the cutting blade to adjust the distance between an upper surface of the rotating disk and the cutting blade. The food processing device also includes an adjustment assembly operable to move the rotating disk relative to the cutting blade. The adjustment assembly includes a control knob coupled to the blade assembly and is positioned above the upper surface of the rotating disk, and a threaded sleeve coupled to the rotating disk and is positioned in the control knob.

In some embodiments, the rotating disk may divide the processing chamber into an upper compartment and a lower compartment, and the blade assembly may include a mounting arm having a ramp defined therein to guide food items from the upper compartment to the lower compartment. In some embodiments, the ramp may have an inclined surface extending outwardly in a radial direction from a first end to a second end.

The inclined surface may have a first angle of inclination at the first end and a second angle of inclination at the second end. In some embodiments, the first angle of inclination may be greater than or equal to the second angle of inclination. Additionally, in some embodiments, the first angle of inclination may be approximately 25 degrees. In some embodiments, the second angle of inclination may be approximately 15 degrees.

In some embodiments, the rotating disk may have a counterweight secured thereto, and the threaded sleeve may be positioned between the mounting arm and the counterweight. In some embodiments, rotation of the control knob in a first direction may cause upward movement of the rotating disk, and rotation of the control knob in a second direction may cause downward movement of the rotating disk.

In some embodiments, the blade assembly may include a central shaft coupled to the control knob, and the central shaft may be received in the threaded sleeve. Rotation of the control knob may cause the threaded sleeve to move upwardly and downwardly along the central shaft.

According to another aspect, a food slicer assembly for a food processor is disclosed. The food slicer assembly includes a cutting blade, a mounting arm, which has a ramp defined therein, that is positioned below the cutting blade, and a rotating disk movable to a plurality of positions relative to the cutting blade to adjust the distance between its upper surface and the cutting blade. An adjustment assembly is operable to move the rotating disk relative to the cutting blade. The adjustment assembly includes an internally-threaded control knob positioned above the upper surface of the rotating disk, and an externally-threaded sleeve coupled to the rotating disk that is positioned in the control knob.

In some embodiments, the food slicer assembly may further include a central shaft that is coupled at an upper end to the control knob and is positioned in the sleeve. The mounting arm may extend outwardly from a first end secured to the central shaft to a second end positioned adjacent to an outer rim of the rotating disk. In some embodiments, the ramp may have an inclined surface extending in a radial direction from the first end of the mounting arm to the second end of the mounting arm. The inclined surface may have a first angle of inclination at the first end that is greater than or equal to a second angle of inclination at the second end. In some embodiments, the rotating disk may include a counterweight, and the sleeve may be positioned between the counterweight and the mounting arm.

According to another aspect, a food processor includes a base having a motor positioned therein, a removable bowl coupled to the base, and a removable lid coupled to the bowl so as to define a processing chamber. The lid has a feed tube that opens into the bowl. A cutting blade is positioned in the bowl and driven by the motor to cut food items advanced through the feed tube. A rotating disk is upwardly and downwardly movable relative to the cutting blade to adjust the distance therebetween. The rotating disk divides the processing chamber into an upper compartment and a lower compartment. A ramp is positioned below the cutting blade to guide food items from the upper compartment into the lower compartment. The food processor further includes an adjustment assembly operable to move the rotating disk relative to the cutting blade. The adjustment assembly includes a user-operated control device positioned above the rotating disk.

In some embodiments, the adjustment assembly may include an externally-threaded sleeve coupled to the rotating disk, and the user-operated control device may include an internally-threaded control knob having a grip.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring toFIGS. 1-6, a food processor10is shown. One example of a food processor is the KitchenAid® 12-Cup Ultra Wide Mouth™ Food Processor, Base Model No. KFPW760OB, which is commercially available from Whirlpool Corporation of Benton Harbor, Mich., U.S.A. The food processor10has a base12that houses a motor14(shown schematically inFIG. 2) and a control unit (not shown). Under the control of the control unit, the motor's output shaft16drives a cutting blade18(seeFIG. 2) to cut food items such as cheeses, meats, fruits, and vegetables. The base12also includes one or more buttons, switches, dials, or other types of controls20. A user operates the controls20to control the operation of the motor14and hence the food processor10. For instance, one of the controls20may be operable to turn the motor14on and off, while another control20may change the motor's speed.

As will be understood by those skilled in the art, the control unit may comprise analog and/or digital circuitry to process electrical signals received from the motor14(or other components of the food processor10) and provide electrical control signals to the motor or other components of the food processor10. For example, the control unit may be embodied as a microcontroller that executes firmware routines to control the operation of the food processor10.

A removable bowl22is secured to the base12. The bowl's handle facilitates placement of the bowl22on the base12. The bowl22includes a removable lid26secured to its upper peripheral edge. The lid26has a feed tube28formed thereon through which food items such as cheeses, meats, fruits, and vegetables are inserted into the bowl22to be processed by the food processor10. Collectively, the lid26and the bowl22define a processing chamber24where food items are processed by the cutting blade18.

The bowl22, lid26, and feed tube28are generally made of a transparent or translucent plastic material, so that the contents of the food processor10can be viewed by a user without removing the lid26from the bowl22. Moreover, one or more locking mechanisms may be used to lock the bowl to the base12and the lid26to the bowl22.

As shown inFIGS. 2 and 3, when the removable bowl22is secured to the base12, the output shaft16of the motor14is coupled to a drive stem30. The drive stem30is in turn coupled to a food slicer assembly32. As shown inFIGS. 2-4, the food slicer assembly32includes a rotating disk34and a blade assembly36, with the cutting blade18being one component thereof. The rotating disk34effectively divides the processing chamber24into an upper compartment38located between the disk34and the lid26, and a lower compartment40located below the rotating disk34. A vertical distance, D, between the cutting edge42of the cutting blade18and the upper surface44of the rotating disk34defines a cutting thickness. In other words, the thickness of the pieces of food items cut by the food processor10is determined by the distance D between the cutting edge42of the cutting blade18and the upper surface44of the rotating disk34. When the distance D between the cutting edge42of the cutting blade18and the upper surface44of the rotating disk34is increased, thicker pieces of food items are created, with thinner pieces of food items being created when the distance D between the cutting edge42of the cutting blade18and the upper surface44of the rotating disk34is decreased. As will be discussed in greater detail below, the rotating disk34is movable upwardly or downwardly between a plurality of cutting positions relative to the cutting blade18to vary the cutting thickness of the food processor10, thereby creating thicker or thinner pieces of cut food items.

As shown inFIGS. 2-5, the blade assembly36includes a central shaft46that extends from a lower end48to an upper end50. The lower end48receives the drive stem30, thereby coupling the slicer assembly32to the output shaft16such that the slicer assembly32may be driven by the motor14. The blade assembly36also includes a hub52positioned at the upper end50of the central shaft46. As shown inFIG. 2, a tip54of the hub52is received in a guide sleeve56extending downward from the underside of the lid26.

An inner edge58of the cutting blade18is received in a slot60formed between the hub52and the upper end50of the central shaft46. As shown inFIGS. 2 and 3, the cutting blade18is secured within the slot60such that substantial deflection of the cutting blade18is inhibited when the cutting blade18cuts food items in the processing chamber24. The cutting blade18is also secured to a mounting arm62extending away from the upper end50of the central shaft46to an end64. A number of fasteners66(i.e., screws) positioned at a rear edge68of the cutting blade18extend into the mounting arm62, thereby rigidly securing the cutting blade18to the mounting arm62. It will be appreciated that in other embodiments the fasteners66may take the form of T-stakes, pins, posts, or other structures capable of securing the cutting blade18to the mounting arm62. Additionally, the mounting arm62may include an overmold that receives the cutting blade18.

As shown inFIGS. 2 and 3, the blade assembly36also includes a pair of flanges70extending beyond the end64of the mounting arm62. One of the flanges70is an outer edge72of the cutting blade18. Another flange70is an arcuate-shaped lip74extending outwardly from the end64of the mounting arm62that is parallel to the outer edge72of the cutting blade18. As will be discussed in greater detail below, at least one of the flanges70is received in one of a plurality of slots76formed in the rotating disk34at each of the cutting positions.

The rotating disk34includes a planar body80and a central sleeve82extending downwardly from a lower surface84thereof. It will be appreciated that one or more of the components of the rotating disk34may be formed from plastic or a metallic material. The rotating disk34includes a passageway86that extends through the sleeve82and receives the central shaft46of the blade assembly36. The planar body80also has a contoured opening88extending from the upper surface44to the lower surface84. The contoured opening88is sized to receive the mounting arm62of the blade assembly36. When the blade assembly36is positioned in the rotating disk34, a gap or throat92is defined between the cutting edge42and the body80, as shown inFIG. 4.

During operation, the motor14causes the blade assembly36to rotate. The blade assembly36acts on a sidewall94of the sleeve82such that the rotating disk34and the blade assembly36rotate together. Food items inserted through the feed tube28are urged into contact with the upper surface44of the rotating disk34while being acted upon (i.e., cut) by the cutting blade18. Cut food items, along with other food items small enough to fit within the throat92, pass from the upper compartment38into the lower compartment40through the throat92.

As best seen inFIGS. 2, 3, and 5, the mounting arm62has a ramp95defined therein, which guides food items from the throat92into the lower compartment40of the bowl22. The surface96of the ramp95is sloped downward from an upper end97positioned adjacent to the cutting edge42to a lower end98. As shown inFIG. 5, the surface96extends radially outward from the central shaft46to the end64of the mounting arm62. The angle of inclination or slope of the surface96changes along the radially length of the surface96, increasing from approximately 15 degrees at the end64to approximately 25 degrees near the central shaft46. As shown inFIG. 5, the surface96has an angle of inclination α of approximately 22 degrees. In other embodiments, the surface96may be convex or concave in one or more directions. The central shaft46and the end64of the mounting arm62act as sidewalls for the surface96such that food items entering the throat92are guided down the ramp95. In that way, the surface96is encapsulated or captured, thereby reducing the potential for food items to travel outside of the processing path and thus reducing unwanted debris.

A rim90extends upwardly from the outer perimeter of the disk's planar body80. The rotating disk34has a diameter that is slightly less than the inner diameter of the bowl22such that the rim90is positioned adjacent to, but spaced slightly apart from, the inner wall of the bowl to permit rotation of the disk34within the bowl22. The rotating disk34also includes a blade support100pivotably coupled to the rim90.

As best seen inFIG. 6, the blade support100has the plurality of slots76formed therein. Each of the slots76extends parallel to the outer edge72of the cutting blade18, and each of the slots76is sized to receive one of the flanges70. In the illustrative embodiment, five slots76are formed in the blade support100, and the slots76are spaced apart from each other by two millimeters. It will be appreciated that in other embodiments the blade support100may include additional or fewer slots and the spacing between the slots may be adjusted.

The blade support100has a body102extending from an end104hinged to the rim90at a pivot joint106. The pivot joint106includes a cylindrical pivot pin108that extends through, and is positioned in, the rim90and the end104. It will be appreciated that in other embodiments the pivot pin108may be formed as part of the blade support100. As shown inFIGS. 4 and 6, the blade support100pivots relative to the rim90about an axis112defined by the pivot joint106between an engaged position and a disengaged position.

When the blade support100is in the engaged position (seeFIGS. 2 and 3), one of the flanges70of the blade assembly36is received in a corresponding slot76. In the engaged position, the body102is fully positioned in an opening110formed in the rim90. When the blade support100is pivoted to the disengaged position, the body102extends outwardly from the opening110, as shown inFIG. 6. In the disengaged position, the slots76are spaced apart from the flanges70of the blade assembly36.

The rotating disk34includes a locking device114that secures the blade support100in the engaged position. In the illustrative embodiment, the locking device114includes a rectangular tab116extending from an end118of the body102. When the blade support100is in the engaged position, the tab116is received in a recess120formed in the rim90. Another recess122formed in the end118of the body102permits a user to apply sufficient force to release the blade support100. It will be appreciated that in other embodiments the locking device114may take the form of a latch, pin, or other mechanism configured to maintain the blade support100in the engaged position.

As discussed above, the rotating disk34is movable upwardly and downwardly between a plurality of cutting positions relative to the cutting blade18. As shown inFIG. 2, in one cutting position of the rotating disk34, the outer edge72of the cutting blade18is received in the upper slot124of the blade support100. In another cutting position, the lip74of the mounting arm62is received in the upper slot124of the blade support100. In other cutting positions, the lip74may be positioned in any of the other slots76of the blade support100. It will be appreciated that in other embodiments both flanges70of the blade assembly36may be received in slots76of the rotating disk34. Additionally, in other embodiments, the blade assembly36may include only a single flange70, such as, for example, the outer edge72of the cutting blade, which is received in a slot76at each of the cutting positions. In addition to providing support to the cutting blade18, the engagement of one of the flanges70with one of the slots76inhibits or prevents the upward and downward movement of the rotating disk34when the blade support100is in the engaged position.

As shown inFIGS. 2 and 3, the food slicer assembly32includes a separate locking mechanism130positioned below the lower surface84of the rotating disk34that is configured to prevent the upward and downward movement of the rotating disk34. In that way, the rotating disk34can be locked at one cutting position relative to the cutting blade18. In the illustrative embodiment, the locking mechanism130is also configured to prevent the blade assembly36from rotating relative to the rotating disk34.

As shown inFIGS. 2 and 3, the locking mechanism130includes a user-operated pin132. The term “user-operated pin” as used herein refers to a pin that is manually operated by the user without the use of a tool. This is distinct from, and in contrast to, a set screw, hex bolt, or other fastener that is operated by the user through the use of a wrench, screw driver, or other tool. The user-operated pin132includes an elongated shaft134extending from an end136positioned outside of the sleeve82to an end138positioned in an aperture140defined in the central shaft46. A button-head142sized to receive a finger of a user is formed at the end136of the shaft134. The outer surface144of the shaft134includes a smooth section146and another section having a plurality of teeth148extending therefrom.

The shaft134of the user-operated pin132extends through a vertically-extending slot150defined in the sidewall94of the sleeve82. The sidewall94includes a plurality of teeth152that extend into the slot150. As indicated by arrow154inFIG. 2, the shaft134is movable between a locked position, in which the teeth148of the shaft134interdigitate or engage with a number of the teeth152of the sidewall94, and an unlocked position, in which the teeth148of the user-operated pin are spaced apart from the teeth152of the sleeve. In the locked position, the rotating disk34is prevented from moving upward and downward relative to the cutting blade18. It will be appreciated that in other embodiments the central shaft46may have a number of teeth configured to engage with the teeth148of the user-operated pin132. It will also be appreciated that in other embodiments the user-operated pin132, central shaft46, and sleeve82may have any combination of slots, grooves, flanges, or other structures suitable for locking the rotating disk34in position relative to the cutting blade18.

As shown inFIGS. 2 and 3, the aperture140defined in the central shaft46extends inwardly to a bottom160. A cylindrical guide pin162is positioned in an opening164formed at the bottom160of the aperture140and extends away from the bottom160to an end. A spring168extends over the guide pin162is coupled at a spring end170to the end138of the user-operated pin132. It will be appreciated that in other embodiments the guide pin162may take the form of a cross, hexagon, or other shape to provide guidance and stability to the spring168. The spring168biases the user-operated pin132away from the bottom160of the aperture140thereby engaging the teeth148of the user-operated pin with the teeth152of the sleeve.

To change the distance D between the cutting edge42of the cutting blade18and the upper surface44of the rotating disk34, the user unlocks the blade support100from the rim90and pivots the blade support100about the axis112from the engaged position to the disengaged position. The user then presses the button-head142to depress the user-operated pin132. The spring168is compressed and the teeth148are moved out of contact with the teeth152of the sleeve82. When the teeth148of the user-operated pin are spaced apart from the teeth152of the sleeve, the user may slide the rotating disk34upwardly or downwardly to another cutting position.

Once the rotating disk34is at the desired cutting position, the user releases the button-head142, and the spring168urges the user-operated pin132away from the bottom160of the aperture140, thereby reengaging the teeth148with the teeth152and locking the rotating disk34into the desired cutting position. The user pivots the blade support100from the disengaged position back to the engaged position, thereby preventing substantial deflection of the cutting blade18and providing an additional locking feature to prevent the upward/downward movement of the rotating disk34relative to the cutting blade18.

It will be appreciated that in other embodiments the slicer assembly32may not include the blade support100. In such embodiments, changing the distance D between the cutting edge42of the cutting blade18and the upper surface44of the rotating disk34would involve operating only the user-operated pin132of the locking mechanism130. Similarly, in other embodiments including the blade support100, the locking mechanism130may be omitted and replaced with a different thickness adjustment assembly operable by a user to vary the cutting thickness of the food processor10. In those embodiments, changing the distance D between the cutting edge42of the cutting blade18and the upper surface44of the rotating disk34would involve, first, moving the blade support100to the disengaged position, which would release the rotating disk34for upward and downward movement, and, second, operating the thickness adjustment assembly.

Referring now toFIGS. 7 and 8, another embodiment of a food slicer assembly is shown in a food processor. Many of the components of the food processor ofFIGS. 7 and 8are common with the components of the food processor ofFIGS. 1-6. Such common components have common reference numerals. The food processor ofFIGS. 7 and 8is essentially the same as the food processor ofFIGS. 1-6except that the food slicer assembly (hereinafter food slicer assembly200) includes a different locking mechanism to prevent the upward and downward movement rotating disk34relative to the cutting blade18.

The slicer assembly200, like the slicer assembly32described above in reference toFIGS. 1-6, includes a blade assembly36and a rotating disk34. In addition to the cutting blade18, the blade assembly36includes a central shaft202extending from an upper end204to a lower end206. The lower end206receives the drive stem30, thereby coupling the slicer assembly200to the motor14. As shown inFIGS. 7 and 8, one section208of central shaft202has a plurality of teeth210extending outwardly from an outer surface212thereof.

The rotating disk34includes a central sleeve214extending downwardly from a lower surface84thereof. A passageway216extends through the sleeve214and receives the central shaft202of the blade assembly36. Similar to the locking mechanism130described above in reference toFIGS. 1-6, a pair of locking mechanisms230are positioned below the lower surface84of the rotating disk34.

Each locking mechanism230includes a user-operated pin232and a lever234coupled thereto. The user-operated pin232includes a shaft236that is positioned in a through-hole238formed in a sidewall240of the sleeve214. The shaft236extends from an end242positioned outside of the sleeve214to an end244positioned in the passageway216. The user-operated pin232moves back and forth within the through-hole238, as indicated by arrow246, between a locked position and an unlocked position.

The lever234is positioned within the passageway216and is pivotably coupled to the sidewall240of the sleeve214. The lever234has a lever body250that extends from an upper end252to a lower end254. The upper end252of lever body250includes a tip256that is sized to engage with the teeth210formed on the central shaft202. The lower end254is coupled to the end244of the user-operated pin232. As shown inFIGS. 7 and 8, the ends244,254are in contact but are not fixed to each other. It will be appreciated that in other embodiments the ends244,254may be pivotably fastened together.

The lever body250is pivotably coupled to the sidewall240at a pivot joint260. The pivot joint260includes a cylindrical pivot pin262that extends through lever body250and the sidewall240. The lever body250pivots about an axis defined by the pivot joint260between an engaged position and a disengaged position. In the engaged position, the tip256of the lever234is engaged with a number of the teeth210of the central shaft202. When the lever234is in the engaged position, the rotating disk34is prevented from moving relative to the cutting blade18. In the disengaged position, the tip256of the lever is spaced apart from the teeth210of the central shaft202such that the lever234does not prevent the rotating disk34from being moved to another cutting position.

A spring266is positioned in the passageway216of the sleeve214and is coupled to the upper end252of the lever body250. The spring266extends from a spring end268coupled to the lever body250to a spring end270coupled to the sidewall240of the sleeve214. The spring266biases the upper end252of the lever234toward the central shaft202thereby engaging the tip256with the teeth210of the central shaft202.

When the user depresses the user-operated pin232of each locking mechanism230, the user-operated pin232is moved from the locked position to the unlocked position. The shaft236of the user-operated pin232acts on the lower end254of the lever234, thereby causing the lever234to pivot from the engaged position to the disengaged position. As the upper end252moves away from the central shaft202, the spring266is compressed. Thus, when the user-operated pin232is in the unlocked position, the lever234is in the disengaged position.

When the user releases the user-operated pin232, the spring266urges the upper end252toward the central shaft202thereby re-engaging the tip256with the teeth210. As the lever234moves back to the engaged position, the lever body250urges the user-operated pin232back to the locked position.

For example, while food processor10is herein illustrated as a conventional domestic food processor, the features and aspects disclosed herein can also be implemented in other types of food processing devices such as automatic food slicers, dicers, ice shavers and the like. Similarly, the blade support could be removable from the rotating disk34instead of being pivotably coupled to the rim. Additionally, the rotating disk could be directly coupled to the motor, and the blade could be movable relative to the rotating disk.

Referring toFIGS. 9-14, a food processor310is shown. One example of a food processor is the KitchenAid® 12-Cup Ultra Wide Mouth™ Food Processor, Base Model No. KFPW760OB, which is commercially available from Whirlpool Corporation of Benton Harbor, Mich., U.S.A. The food processor310has a base312that houses a motor314(shown schematically inFIG. 10) and a control unit (not shown). Under the control of the control unit, the motor's output shaft316drives a cutting blade318(seeFIG. 10) to cut food items such as cheeses, meats, fruits, and vegetables. The base312also includes one or more buttons, switches, dials, or other types of controls320. A user operates the controls320to control the operation of the motor314and hence the food processor310. For instance, one of the controls320may be operable to turn the motor314on and off, while another control320may change the motor's speed.

As will be understood by those skilled in the art, the control unit may comprise analog and/or digital circuitry to process electrical signals received from the motor314(or other components of the food processor310) and provide electrical control signals to the motor or other components of the food processor310. For example, the control unit may be embodied as a microcontroller that executes firmware routines to control the operation of the food processor310.

A removable bowl322is secured to the base312. The bowl's handle facilitates placement of the bowl322on the base312. The bowl322includes a removable lid326secured to its upper peripheral edge. The lid326has a feed tube328formed thereon through which food items such as cheeses, meats, fruits, and vegetables are inserted into the bowl322to be processed by the food processor310. Collectively, the lid326and the bowl322define a processing chamber324where food items are processed by the cutting blade318.

The bowl322, lid326, and feed tube328are generally made of a transparent or translucent plastic material, so that the contents of the food processor310can be viewed by a user without removing the lid326from the bowl322. Moreover, one or more locking mechanisms may be used to lock the bowl to the base312and the lid326to the bowl322.

As shown inFIGS. 10 and 11, when the removable bowl322is secured to the base312, the output shaft316of the motor314is coupled to a drive stem330. The drive stem330is in turn coupled to a food slicer assembly332. As shown inFIGS. 10-12, the food slicer assembly332includes a rotating disk334and a blade assembly336, with the cutting blade318being one component thereof. The rotating disk334effectively divides the processing chamber324into an upper compartment338located between the disk334and the lid326, and a lower compartment340located below the rotating disk334. A vertical distance, D, between the cutting edge342of the cutting blade318and the upper surface344of the rotating disk334defines a cutting thickness. In other words, the thickness of the pieces of food items cut by the food processor310is determined by the distance D between the cutting edge342of the cutting blade18and the upper surface344of the rotating disk334. When the distance D between the cutting edge342of the cutting blade318and the upper surface344of the rotating disk334is increased, thicker pieces of food items are created, with thinner pieces of food items being created when the distance D between the cutting edge342of the cutting blade318and the upper surface344of the rotating disk334is decreased. As will be discussed in greater detail below, the rotating disk334is movable upwardly or downwardly between a plurality of cutting positions relative to the cutting blade318to vary the cutting thickness of the food processor310, thereby creating thicker or thinner pieces of cut food items.

As shown inFIGS. 10-13, the blade assembly336includes a central shaft346that extends from a lower end348to an upper end350. The lower end348receives the drive stem330, thereby coupling the slicer assembly332to the output shaft316such that the slicer assembly332may be driven by the motor314. The blade assembly336also includes a hub352positioned at the upper end350of the central shaft346. As shown inFIG. 10, a tip354of the hub352is received in a guide sleeve356extending downward from the underside of the lid326.

An inner edge358of the cutting blade318is received in a slot360formed between the hub352and the upper end350of the central shaft346. As shown inFIGS. 10 and 11, the cutting blade318is secured within the slot360such that substantial deflection of the cutting blade318is inhibited when the cutting blade318cuts food items in the processing chamber324. The cutting blade318is also secured to a mounting arm362extending away from the upper end350of the central shaft346to an end364. A number of fasteners366(i.e., screws) (FIG. 12) positioned at a rear edge368of the cutting blade318extend into the mounting arm362, thereby rigidly securing the cutting blade318to the mounting arm362. It will be appreciated that in other embodiments the fasteners366may take the form of T-stakes, pins, posts, or other structures capable of securing the cutting blade18to the mounting arm362. Additionally, the mounting arm362may include an overmold that receives the cutting blade318.

As shown inFIGS. 10 and 11, the blade assembly336also includes a pair of flanges370extending beyond the end364of the mounting arm362. One of the flanges370is an outer edge372of the cutting blade318. Another flange370is an arcuate-shaped lip374extending outwardly from the end364of the mounting arm362that is parallel to the outer edge372of the cutting blade318. As will be discussed in greater detail below, at least one of the flanges370is received in one of a plurality of slots376formed in the rotating disk334at each of the cutting positions.

The rotating disk334includes a planar body380and a central sleeve382extending downwardly from a lower surface384thereof. It will be appreciated that one or more of the components of the rotating disk334may be formed from plastic or a metallic material. The rotating disk334includes a passageway386that extends through the sleeve382and receives the central shaft346of the blade assembly336. The planar body380also has a contoured opening388extending from the upper surface344to the lower surface384. The contoured opening388is sized to receive the mounting arm362of the blade assembly336. When the blade assembly336is positioned in the rotating disk334, a gap or throat392is defined between the cutting edge342and the body380, as shown inFIG. 12.

During operation, the motor314causes the blade assembly336to rotate. The blade assembly336acts on a sidewall394of the sleeve382such that the rotating disk334and the blade assembly336rotate together. Food items inserted through the feed tube328are urged into contact with the upper surface344of the rotating disk334while being acted upon (i.e., cut) by the cutting blade318. Cut food items, along with other food items small enough to fit within the throat392, pass from the upper compartment338into the lower compartment340through the throat392.

As best seen inFIG. 13, the mounting arm362has a ramp395defined therein, which guides food items from the throat392into the lower compartment340of the bowl322. The surface396of the ramp395is sloped downward from an upper end397positioned adjacent to the cutting edge342to a lower end398. As shown inFIGS. 10 and 11, the surface396extends radially outward from the central shaft346to the end364of the mounting arm362. The angle of inclination or slope of the surface396changes along the radially length of the surface396, increasing from approximately 15 degrees at the end364to approximately 25 degrees near the central shaft346. As shown inFIG. 13, the surface396has an angle of inclination α of approximately 22 degrees. In other embodiments, the surface396may be convex or concave in one or more directions. The central shaft346and the end364of the mounting arm362act as sidewalls for the surface396such that food items entering the throat392are guided down the ramp395. In that way, the surface396is encapsulated or captured, thereby reducing the potential for food items to travel outside of the processing path and thus reducing unwanted debris.

A rim390extends upwardly from the outer perimeter of the disk's planar body380. The rotating disk334has a diameter that is slightly less than the inner diameter of the bowl322such that the rim390is positioned adjacent to, but spaced slightly apart from, the inner wall of the bowl to permit rotation of the disk334within the bowl322. The rotating disk334also includes a blade support400pivotably coupled to the rim90.

As best seen inFIG. 14, the blade support400has the plurality of slots376formed therein. Each of the slots376extends parallel to the outer edge372of the cutting blade318, and each of the slots376is sized to receive one of the flanges370. In the illustrative embodiment, five slots376are formed in the blade support400, and the slots376are spaced apart from each other by two millimeters. It will be appreciated that in other embodiments the blade support400may include additional or fewer slots and the spacing between the slots may be adjusted.

The blade support400has a body402extending from an end404hinged to the rim390at a pivot joint406. The pivot joint406includes a cylindrical pivot pin408that extends through, and is positioned in, the rim390and the end404. It will be appreciated that in other embodiments the pivot pin408may be formed as part of the blade support400. As shown inFIGS. 12 and 14, the blade support400pivots relative to the rim390about an axis412defined by the pivot joint406between an engaged position and a disengaged position.

When the blade support400is in the engaged position (seeFIGS. 10 and 11), one of the flanges370of the blade assembly336is received in a corresponding slot376. In the engaged position, the body402is fully positioned in an opening410formed in the rim390. When the blade support400is pivoted to the disengaged position, the body402extends outwardly from the opening410, as shown inFIG. 14. In the disengaged position, the slots376are spaced apart from the flanges370of the blade assembly336.

The rotating disk334includes a locking device414that secures the blade support400in the engaged position. In the illustrative embodiment, the locking device414includes a rectangular tab416extending from an end418of the body402. When the blade support400is in the engaged position, the tab416is received in a recess420formed in the rim390. Another recess422formed in the end418of the body402permits a user to apply sufficient force to release the blade support400. It will be appreciated that in other embodiments the locking device414may take the form of a latch, pin, or other mechanism configured to maintain the blade support400in the engaged position.

As discussed above, the rotating disk334is movable upwardly and downwardly between a plurality of cutting positions relative to the cutting blade318. As shown inFIG. 10, in one cutting position of the rotating disk334, the outer edge372of the cutting blade318is received in the upper slot424of the blade support400. In another cutting position, the lip374of the mounting arm362is received in the upper slot424of the blade support400. In other cutting positions, the lip374may be positioned in any of the other slots376of the blade support400. It will be appreciated that in other embodiments both flanges370of the blade assembly336may be received in slots376of the rotating disk334. Additionally, in other embodiments, the blade assembly336may include only a single flange370, such as, for example, the outer edge372of the cutting blade, which is received in a slot376at each of the cutting positions. In addition to providing support to the cutting blade318, the engagement of one of the flanges370with one of the slots376inhibits or prevents the upward and downward movement of the rotating disk334when the blade support400is in the engaged position.

As shown inFIGS. 10 and 11, the food slicer assembly332includes a separate locking mechanism430positioned below the lower surface384of the rotating disk334that is configured to prevent the upward and downward movement of the rotating disk334. In that way, the rotating disk334can be locked at one cutting position relative to the cutting blade318. In the illustrative embodiment, the locking mechanism430is also configured to prevent the blade assembly336from rotating relative to the rotating disk334.

As shown inFIGS. 10 and 11, the locking mechanism430includes a user-operated pin432. The term “user-operated pin” as used herein refers to a pin that is manually operated by the user without the use of a tool. This is distinct from, and in contrast to, a set screw, hex bolt, or other fastener that is operated by the user through the use of a wrench, screw driver, or other tool. The user-operated pin432includes an elongated shaft434extending from an end436positioned outside of the sleeve382to an end438positioned in an aperture440defined in the central shaft346. A button-head442sized to receive a finger of a user is formed at the end436of the shaft434. The outer surface444of the shaft434includes a smooth section446and another section having a plurality of teeth448extending therefrom.

The shaft434of the user-operated pin432extends through a vertically-extending slot450defined in the sidewall394of the sleeve382. The sidewall394includes a plurality of teeth452that extend into the slot450. As indicated by arrow454inFIG. 10, the shaft434is movable between a locked position, in which the teeth448of the shaft434interdigitate or engage with a number of the teeth452of the sidewall394, and an unlocked position, in which the teeth348of the user-operated pin are spaced apart from the teeth352of the sleeve. In the locked position, the rotating disk334is prevented from moving upward and downward relative to the cutting blade318. It will be appreciated that in other embodiments the central shaft346may have a number of teeth configured to engage with the teeth448of the user-operated pin432. It will also be appreciated that in other embodiments the user-operated pin432, central shaft346, and sleeve382may have any combination of slots, grooves, flanges, or other structures suitable for locking the rotating disk334in position relative to the cutting blade318.

As shown inFIGS. 10 and 11, the aperture440defined in the central shaft346extends inwardly to a bottom460. A cylindrical guide pin462is positioned in an opening464formed at the bottom460of the aperture440and extends away from the bottom460to an end. A spring368extends over the guide pin462and is coupled at a spring end470to the end438of the user-operated pin432. It will be appreciated that in other embodiments the guide pin462may take the form of a cross, hexagon, or other shape to provide guidance and stability to the spring468. The spring468biases the user-operated pin432away from the bottom460of the aperture440thereby engaging the teeth448of the user-operated pin with the teeth452of the sleeve.

To change the distance D between the cutting edge442of the cutting blade418and the upper surface344of the rotating disk334, the user unlocks the blade support400from the rim390and pivots the blade support400about the axis412from the engaged position to the disengaged position. The user then presses the button-head442to depress the user-operated pin432. The spring468is compressed and the teeth448are moved out of contact with the teeth452of the sleeve382. When the teeth448of the user-operated pin are spaced apart from the teeth452of the sleeve, the user may slide the rotating disk334upwardly or downwardly to another cutting position.

Once the rotating disk334is at the desired cutting position, the user releases the button-head442, and the spring468urges the user-operated pin432away from the bottom460of the aperture440, thereby reengaging the teeth448with the teeth452and locking the rotating disk334into the desired cutting position. The user pivots the blade support400from the disengaged position back to the engaged position, thereby preventing substantial deflection of the cutting blade318and providing an additional locking feature to prevent the upward/downward movement of the rotating disk334relative to the cutting blade318.

It will be appreciated that in other embodiments the slicer assembly332may not include the blade support400. In such embodiments, changing the distance D between the cutting edge342of the cutting blade318and the upper surface344of the rotating disk334would involve operating only the user-operated pin432of the locking mechanism430. Similarly, in other embodiments including the blade support400, the locking mechanism430may be omitted and replaced with a different thickness adjustment assembly operable by a user to vary the cutting thickness of the food processor310. In those embodiments, changing the distance D between the cutting edge342of the cutting blade318and the upper surface344of the rotating disk334would involve, first, moving the blade support400to the disengaged position, which would release the rotating disk334for upward and downward movement, and, second, operating the thickness adjustment assembly.

Referring now toFIGS. 15 and 16another embodiment of a food slicer assembly is shown in a food processor. Many of the components of the food processor ofFIGS. 15 and 16are common with the components of the food processor ofFIGS. 9-14. Such common components have common reference numerals. The food processor ofFIGS. 15 and 16is essentially the same as the food processor ofFIGS. 9-14except that the food slicer assembly (hereinafter food slicer assembly500) includes a different locking mechanism to prevent the upward and downward movement rotating disk334relative to the cutting blade318.

The slicer assembly500, like the slicer assembly332described above in reference toFIGS. 9-14, includes a blade assembly336and a rotating disk334. In addition to the cutting blade318, the blade assembly336includes a central shaft502extending from an upper end504to a lower end506. The lower end506receives the drive stem330, thereby coupling the slicer assembly500to the motor314. As shown inFIGS. 15 and 16, one section508of central shaft502has a plurality of teeth510extending outwardly from an outer surface512thereof.

The rotating disk334includes a central sleeve514extending downwardly from a lower surface384thereof. A passageway516extends through the sleeve514and receives the central shaft502of the blade assembly336. Similar to the locking mechanism430described above in reference toFIGS. 9-14, a pair of locking mechanisms530are positioned below the lower surface384of the rotating disk334.

Each locking mechanism530includes a user-operated pin532and a lever534coupled thereto. The user-operated pin532includes a shaft536that is positioned in a through-hole538formed in a sidewall540of the sleeve514. The shaft536extends from an end542positioned outside of the sleeve514to an end544positioned in the passageway516. The user-operated pin532moves back and forth within the through-hole538, as indicated by arrow546, between a locked position and an unlocked position.

The lever534is positioned within the passageway516and is pivotably coupled to the sidewall541of the sleeve514. The lever534has a lever body550that extends from an upper end552to a lower end554. The upper end552of lever body550includes a tip556that is sized to engage with the teeth510formed on the central shaft502. The lower end554is coupled to the end544of the user-operated pin532. As shown inFIGS. 15 and 16, the ends544,554are in contact but are not fixed to each other. It will be appreciated that in other embodiments the ends544,554may be pivotably fastened together.

The lever body550is pivotably coupled to the sidewall540at a pivot joint560. The pivot joint560includes a cylindrical pivot pin562that extends through lever body550and the sidewall540. The lever body550pivots about an axis defined by the pivot joint560between an engaged position and a disengaged position. In the engaged position, the tip556of the lever534is engaged with a number of the teeth510of the central shaft502. When the lever534is in the engaged position, the rotating disk334is prevented from moving relative to the cutting blade318. In the disengaged position, the tip556of the lever is spaced apart from the teeth510of the central shaft502such that the lever534does not prevent the rotating disk334from being moved to another cutting position.

A spring566is positioned in the passageway516of the sleeve514and is coupled to the upper end552of the lever body550. The spring566extends from a spring end568coupled to the lever body550to a spring end570coupled to the sidewall540of the sleeve514. The spring566biases the upper end552of the lever534toward the central shaft502thereby engaging the tip556with the teeth510of the central shaft502.

When the user depresses the user-operated pin532of each locking mechanism530, the user-operated pin532is moved from the locked position to the unlocked position. The shaft536of the user-operated pin532acts on the lower end554of the lever534, thereby causing the lever534to pivot from the engaged position to the disengaged position. As the upper end552moves away from the central shaft502, the spring566is compressed. Thus, when the user-operated pin532is in the unlocked position, the lever534is in the disengaged position.

When the user releases the user-operated pin532, the spring566urges the upper end552toward the central shaft502thereby re-engaging the tip556with the teeth510. As the lever534moves back to the engaged position, the lever body550urges the user-operated pin532back to the locked position.

For example, while food processor310is herein illustrated as a conventional domestic food processor, the features and aspects disclosed herein can also be implemented in other types of food processing devices such as automatic food slicers, dicers, ice shavers and the like. Similarly, the blade support could be removable from the rotating disk334instead of being pivotably coupled to the rim. Additionally, the rotating disk could be directly coupled to the motor, and the blade could be movable relative to the rotating disk.

Referring toFIG. 17, a food processing device or food processor610is shown. One example of a food processor is the KitchenAid® 12-Cup Ultra Wide Mouth™ Food Processor, Base Model No. KFPW760OB, which is commercially available from Whirlpool Corporation of Benton Harbor, Mich., U.S.A. The food processor610has a base612that houses a motor614(shown schematically inFIG. 18) and a control unit (not shown). Under the control of the control unit, the motor's output shaft616drives a cutting blade618(seeFIG. 18) to cut food items such as cheeses, meats, fruits, and vegetables. The base612also includes one or more buttons, switches, dials, or other types of controls620. A user operates the controls620to control the operation of the motor614and hence the food processor610. For instance, one of the controls620may be operable to turn the motor614on and off, while another control620may change the motor's speed.

As will be understood by those skilled in the art, the control unit may comprise analog and/or digital circuitry to process electrical signals received from the motor614(or other components of the food processor610) and provide electrical control signals to the motor or other components of the food processor610. For example, the control unit may be embodied as a microcontroller that executes firmware routines to control the operation of the food processor610.

A removable bowl622is secured to the base612. The bowl's handle facilitates placement of the bowl622on the base612. The bowl622includes a removable lid626secured to its upper peripheral edge. The lid626has a feed tube628formed thereon through which food items such as fruits and vegetables are inserted into the bowl622to be processed by the food processor610. Collectively, the lid626and the bowl622define a processing chamber624where food items are processed by the cutting blade618.

The bowl622, lid626, and feed tube628are generally made of a transparent or translucent plastic material, so that the contents of the food processor610can be viewed by a user without removing the lid626from the bowl622. Moreover, one or more locking mechanisms may be used to lock the bowl to the base612and the lid626to the bowl622.

As shown inFIGS. 18 and 19, when the removable bowl622is secured to the base612, the output shaft616of the motor614is coupled to a drive stem630. The drive stem630is in turn coupled to a food slicer assembly632. As shown inFIGS. 18-20, the food slicer assembly632includes a rotating disk634, a thickness adjustment assembly636, and a blade assembly638, with the cutting blade618being one component thereof. The rotating disk634effectively divides the processing chamber624into an upper compartment640located between the disk634and the lid626, and a lower compartment642located below the rotating disk634. A vertical distance, D, between the cutting edge644of the cutting blade618and the upper surface646of the rotating disk634defines a cutting thickness. In other words, the thickness of the pieces of food items cut by the food processor610is determined by the distance D between the cutting edge644of the cutting blade618and the upper surface646of the rotating disk634. When the distance D between the cutting edge644of the cutting blade618and the upper surface646of the rotating disk634is increased, thicker pieces of food items are created, with thinner pieces of food items being created when the distance D between the cutting edge644of the cutting blade618and the upper surface646of the rotating disk634is decreased.

The rotating disk634includes a planar body652and a rim654that extends upwardly from the outer perimeter of the planar body652. The rotating disk634has a diameter that is slightly less than the inner diameter of the bowl622such that the rim654is positioned adjacent to, but spaced slightly apart from, the inner wall of the bowl to permit rotation of the disk634within the bowl622. In the exemplary embodiment described herein, the rotating disk634is embodied as a monolithic structure (e.g., a single molded or cast part). However, it should be appreciated that the components of the rotating disk634(e.g., body652and rim654) may be embodied as separate components secured to one another by an adhesive or other suitable fastener.

The thickness adjustment assembly636is operable by a user to vary the cutting thickness of the food processor610thereby creating thicker or thinner pieces of cut food items. The adjustment assembly636includes a hub660and a user-operated control device662. The hub660includes a base664and a hollow sleeve666extending upwardly therefrom. A number of fasteners668(i.e., screws) extend through the planar body652into the base664, thereby rigidly securing the rotating disk634to the hub660. It will be appreciated that in other embodiments the hub660and the rotating disk634may be integrally formed as a monolithic structure. As shown inFIGS. 18 and 19, the sleeve666extends through an opening669formed in the planar body652. External threads670are defined on a portion of an outer surface672of the sleeve666.

The user-operated control device662is positioned above the upper surface646of the rotating disk634. As shown inFIGS. 18-20, the user-operated control device662includes a control knob674. The control knob674has a body676that extends from a lower end678to an upper end680. The body676includes a knurled grip682formed in the upper end680and an annular flange684extending outwardly from the lower end678. It should be appreciated that other user-activated control devices, such as levers, dials, buttons, or the like, may be substituted for the control knob.

As shown inFIGS. 18 and 19, the body676of the control knob674has an aperture686formed in the lower end678that receives the sleeve666of the hub660. The inner surface688of the aperture686has internal threads690defined therein that correspond to the external threads670of the hub660. The internal threads690of the control knob674threadingly engage the external threads670of the hub660to move the hub660(and hence the rotating disk634) upwardly and downwardly relative to the cutting blade618. For example, clockwise rotation of the control knob674causes upward movement of the hub660(and hence the rotating disk634), while counter-clockwise rotation of the control knob674causes downward movement of the hub660(and hence the rotating disk634).

As shown inFIGS. 18 and 19, a central shaft698of the blade assembly638is received in the hollow sleeve666of the adjustment assembly636and is secured at an upper end702to the control knob674. The central shaft698extends from the upper end702to a lower end704, which is has an opening706that receives the drive stem630. In that way, the slicer assembly632is coupled to the output shaft616such that the slicer assembly632may be driven by the motor614. The blade assembly638also includes a mounting arm710extending from an inner end712, which is secured to the lower end704of the central shaft698, to an outer end714, which is positioned adjacent to the rim654of the rotating disk634. In the illustrative embodiment, the central shaft698and mounting arm710are formed as a single monolithic component from a plastic or metallic material. It should be appreciated that in other embodiments the shaft698and arm710may be formed as separate components that are joined during final assembly by an adhesive or other suitable fastener.

The cutting blade618is secured to an upper surface716of the mounting arm710. A number of fasteners720(i.e., screws) positioned at a rear edge722of the cutting blade618extend into the mounting arm710, thereby rigidly securing the cutting blade618to the mounting arm710. It will be appreciated that in other embodiments the fasteners720may take the form of T-stakes, pins, posts, or other structures capable of securing the cutting blade618to the mounting arm710. Additionally, the mounting arm710may include an overmold that receives the cutting blade618.

As shown inFIG. 20, the opening669formed in the planar body652extends radially outward and receives the mounting arm710and the cutting blade618. When the food slicer assembly632is assembled, a gap or throat724is defined between the cutting edge644and the body652, as best seen inFIGS. 20 and 21. The food slicer assembly632also includes a counterweight726coupled to the planar body652adjacent to the outer perimeter of the rotating disk634. As shown inFIGS. 18 and 19, the hub660is positioned between the counterweight726and the cutting blade618. The counterweight726is sized to offset the weight of the mounting arm710and the cutting blade618. In that way, the counterweight726balances the slicer assembly632as it is rotated. In other embodiments, the separate counterweight726may be omitted and additional material may be added to the rim654and the planar body652such that the counterweight is incorporated into the rotating disk634.

During operation, the user may change the cutting position of the rotating disk634using the control knob674. When the control knob674is rotated, the hub660translates upwardly and downwardly along the central shaft698to change the thickness of the food items being processed by the food processor610. In particular, counter-clockwise rotation of the control knob674causes downward movement of the hub660(and hence rotating disk634), which increases the distance D between the cutting edge644of the cutting blade618and the upper surface646of the rotating disk634and thereby produces thicker pieces of food items. Oppositely, when the control knob674is rotated clockwise, the hub660is moved upwardly along the central shaft698and the distance D between the cutting edge644of the cutting blade618and the upper surface646of the rotating disk634is decreased, thereby producing thinner pieces of food items.

When the food processor610is activated, the motor614causes the blade assembly638to rotate. The blade assembly638acts on the hub660secured to the rotating disk634such that the rotating disk634and the blade assembly638rotate together. Food items inserted through the feed tube628are urged into contact with the upper surface646of the rotating disk634while being acted upon (i.e., cut) by the cutting blade618. Cut food items, along with other food items small enough to fit within the throat724, pass from the upper compartment640through the throat724.

A ramp730defined in the mounting arm710guides food items from the upper compartment640to the lower compartment642. As shown inFIG. 21, the ramp730is positioned adjacent to and below the cutting blade618and includes an inclined surface732extending downwardly from the underside of cutting blade618. The inclined surface732extends from the inner end712of the mounting arm710radially outward to the outer end714of the mounting arm710. As shown inFIGS. 18 and 19, the inner end712defines an inner sidewall734for the ramp730, while the outer end714of the mounting arm710defines an outer sidewall736. In that way, the inclined surface732is encapsulated or captured between the sidewalls734,736, thereby reducing the potential for food items to travel outside of the processing path and thus reducing unwanted debris.

As shown inFIGS. 21 and 22, the slope or angle of the inclined surface732relative to the cutting blade618changes as the inclined surface732extends radially outward. As shown inFIG. 21, which is a cross-section of the slicer assembly632taken at the outer end714of the mounting arm710, the inclined surface732has an angle of inclination α at the outer end714. As shown inFIG. 22, which is a cross-section of the slicer assembly632taken at the inner end712of the mounting arm710, the inclined surface732has an angle of inclination ß that is greater than the angle α. In the illustrative embodiment, the angle α is approximately 15 degrees, and the angle ß is approximately 25 degrees. It will be appreciated that in other embodiments the angles α, ß may be greater than or less than those of the illustrative embodiment. Additionally, in some embodiments, the angles α, ß may be equal. In still other embodiments, the inclined surface732may be convex or concave in one or more directions.

For example, while food processing device610is herein illustrated as a conventional domestic food processor, the features and aspects disclosed herein can also be implemented in other types of food processing devices such as automatic food slicers, dicers, ice shavers and the like. Similarly, in other embodiments, the rotating disk could be directly coupled to motor, and the blade could be moveable relative to the rotating disk.