Food processor with a lockable 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. A user-operated pin is positioned below the rotating disk and is moveable between a first position in which the rotating disk is prevented from moving upwardly and downwardly, and a second position in which the rotating disk is permitted to move upwardly and downwardly.

CROSS-REFERENCE TO RELATED U.S. PATENT APPLICATIONS

Cross-reference is made to co-pending U.S. Utility patent application Ser. No. 12/769,709 entitled “Food Processor With Cutting Blade Assembly Support,” filed on Apr. 29, 2010, and U.S. Utility patent application Ser. No. 12/769,796 entitled “Adjustable Food Processor With Guide Ramp,” filed Apr. 29, 2010, each of which is assigned to the same assignee as the present application, each of which is filed concurrently herewith, and each of which is hereby incorporated by reference.

TECHNICAL FIELD

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

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

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 moveable 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 moveable 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 moveable 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 moveable 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 moveable 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.

DETAILED DESCRIPTION OF THE DRAWINGS

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 moveable 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 inFIG. 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 inFIGS. 2 and 3, 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 moveable 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 moveable 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 motor, and the blade could be moveable relative to the rotating disk.