METHOD FOR MAKING FROZEN CONFECTION

Abstract: A method of making a frozen confection in which an individual-serving pastry container (11) is filled with an ice cream substance (12) that extends to form a head (13) on the container top in which method a flavor substance having a specific gravity greater than that of the ice cream is introduced and maintained as a central column (17) extending axially through the length of the ice cream filling and head.

Description: METHOD FOR MAKING FROZEN CONFECTION FIELD OF THE INVENTION This invention relates in general to a frozen confection, such as an ice cream cone, comprising an edible, cone-shape pastry shell forming a container that is filled with a confection substance, such as ice cream, and which confection extends above the open mouth of the container forming a freestanding head. This invention relates more particularly to a frozen confection of this type that includes a central, axially extending column of a flavor substance, forming a core. This invention also relates to a method for forming the frozen confection having the central flavor core. BACKGROUND OF THE INVENTION It is known to produce by machine manufacture frozen confections of the ice cream cone type in which an edible pastry shell or cone is filled with a quantity of the frozen confection. It is also a known practice to fill the cone to substantially its entire extent and then to add a sufficient amount of the confection to form a top or freestanding head. To enhance the flavor aspects of such a confection, it is also a common practice to coat the freestanding head with a layer of flavoring substance, such as chocolate, and also to embed granules or particles of nuts in this layer of chocolate. A confection of this type and the automated apparatus for its fabrication is illustrated in Patent No. 3,580,188, granted May 25, 1971 to Thomas H. Lutsey. That patent is assigned to the same assignee as is the instant invention described in the following specification and illustrated in the accompanying drawings. SUMMARY OF THE INVENTION In accordance with this invention, a frozen confection of the ice cream cone type is provided having enhanced flavor characteristics obtained by the addition of a quantity of a flavor substance other than the chocolate coating and, if desired, in addition to that coating. This other flavor substance, which, may be caramel, is formed as a centrally disposed core extending substantially throughout the entire vertical extent of the ice cream confection in the pastry shell and also forming the freestanding top. This structural configuration of a flavor core results in having a flavoring substance for simultaneous consumption with the ice cream for substantially the entirety of the confection. A method is also provided by this invention for forming a frozen confection having a central flavor core. In accordance with this method, the general procedure consists of filling the container with a frozen confection substance that is at a temperature where its viscosity enables it to be caused to flow from an orifice of a dispensing nozzle. The flavor substance is also maintained at a temperature where its viscosity will enable it to flow from a dispensing nozzle into the center region of the confection and form a central flavor core. Once the container is filled with.- the confection and the flavor core placed in a con ection, the composite unit is subjected to a lower temperature sufficient to result in hardening of the components to the extent that the ice cream will maintain its configuration and where the flavor core will maintain its columnar configuration. One specific method for forming the confection consists of a two-step procedure. First, the confection substance is caused to flow into the container to substantially fill it and also to form a top or head portion extending above the open mouth of the container. While the confection is at this temperature where it is flowable, it still has sufficient viscosity that the head will generally maintain its upstanding configuration with respect to the pastry shell. However, the head will tend to recede because the confection's viscosity is in the range where it is flowable, and the confection will tend to migrate downward and outward resulting in reshaping of the head from a straight columnar configuration as flowed from the dispensing nozzle to a ball or spherically shaped head, particularly during the time that the flavor core is being added and prior to hardening. Once the filling of the container with the confection and forming the head or top is completed, the flavor substance is added by inserting a quill, or hollow, tubular dispensing nozzle into the confection along the central vertical axis of the shell, and then while withdrawing the quill, causing the flavor substance, which is at a flowable viscosity, to exit the nozzle and thereby form the central flavor core. Once the flavor core has been added, the composite unit is quickly placed in a freezing tunnel where the temperature of the composite unit may be lowered to the temperature necessary to solidify the flavor substance as well as to harden the ice cream confection and thereby result in maintaining the configuration of the composite structure. In accordance with a variation of the method, the ice cream confection and flavor core are coaxially dispensed from a coaxial tube nozzle mechanism having each of the two tubes connected in flow-path relationship to respective sources of the ice cream confection and the flavor substance. The combined substances as they exit from the nozzle are placed within the container and a sufficient additional portion added to form the freestanding top. Once the confection and flavor core are thus placed, the composite unit is subjected to a low temperature for effecting further solidification of the materials and increase of their viscosity to the point where they will maintain their structural configurations. These and other objects and advantages of this invention will be readily apparent following the detailed description of the frozen confection and its method of manufacture and from the accompanying drawings illustrative of the article and the method. DESCRIPTION OF THE DRAWING FIGURES Figure 1 is a side elevational view of a frozen confection embodying this invention and formed in accordance with the inventive method. Figure 2 is a medial vertical sectional view on an enlarged scale of the completed confection taken along line 2-2 of Figure 1. Figures 3, 4, 5 and 6 are diagrammatic illustrations of apparatus op-er_ted in performance of the method for forming the frozen confection with, a flavor core. Figures 7 and 8 diagrammatically illustrate forming the confection by the method of concurrent coaxial extrusion or dispensing the frozen confection and flavor substance into a container. Figure 9 is a diagrammatic medial vertical sectional view of a pastry shell filled with an ice cream confection, and a multiple quill-injection apparatus simultaneously forming a plurality of columnar flavor cores. Figure 10 is a sectional view taken along line 9-9 of Figure 9. Figure 11 is a diagrammatic elevational view of a coaxial extrusion assembly similar to that of Figures 7 and 8 for simultaneously forming a plurality of columnar flavor cores. Figure 12 is a sectional view on an enlarged scale taken along line 12-12 of Figure 11. DESCRIPTION OF AN ILLUSTRATIVE EMBODIMENT OF THE INVENTION AND APPARATUS FOR THE METHOD OF FORMING Referring to Figures 1 and 2, there is illustrated a frozen confection that embodies the structure of the invention and that is fabricated in accordance with the method. The frozen confection designated generally by the numeral 10 comprises an edible pastry shell 11 forming a container that is filled with a frozen substance, such as ice cream 12, and has a quantity of the confection substance formed into a top or freestanding head 13 projecting above the open mouth of the shell 11. This top or freestanding head 13 has a generally spherical or ball shape and is advantageously coated with a layer 14 of a flavor substance, such as chocolate. An edible particle or granular material, such as nuts 15, is generally embedded into the layer 14 for additional flavoring. If desired, additional chocolate flavor may be applied to the interior of the pastry shell 11 as an interior coating 16. To simplify illustration of a typical frozen confection embodying this invention, the top T is shown as having a true spherical shape. It is to be understood that the confection as actually produced will not necessarily have a true geometric shape and will most likely have an irregular surface, although of a generally spherical shape. The specific shape and surface characteristics are dependent upon factors such as relative temperatures of the confection and flavorings, and the environment's temperature, taken in conjunction with processing times. The specific shape and surface characteristics of the top T are not limitations on the scope of this invention. The structure as described is essentially the same as that which is shown as being produced by the apparatus disclosed in Patent No. 3,580,188. However, in accordance with this invention, the flavor characteristics of such a confection are further enhanced by the addition of a central core 17, which is formed from another flavoring substance. This flavoring substance may be caramel or it may comprise other flavoring substances that are suitable for formation as a core within the frozen confection. This central core 17 of flavor substance extends throughout substantially the full vertical extent of the confection substance, thus resulting in the additional flavoring being present and consumed throughout the entire process of consuming the confection. The chocolate layer 14 and the nuts 15 being applied only to the exterior of the freestanding head 13 results in those flavoring materials being available only while the head portion of the confection is being consumed. The specific configuration of the flavor core 17 is also not limiting on the scope of the invention except to the extent that the core has a generally cylindrical shape. As will be explained in greater detail in conjunction with the method of forming, the core 17 will most likely not have a true cylindrical shape, but will have an irregular surface configuration as exemplified in Figure 2 of the drawings. In a cone of typical dimension having an open mouth diameter of the order of two (2) inches, the flavor core 17 is formed with a nominal diameter of one fourth (1/4) inch to provide an adequate flavor characteristic with the maximum core diameter being approximately one-half (1/2) inch. In accordance with this invention, forming the frozen confection with the central flavor core can be accomplished by either a two-step or single-step procedure. The apparatus and sequential operation for the two-step procedure is shown in Figures 3-6, whereas the apparatus and procedure for the single-step procedure is shown in Figures 7 and 8. The following description relative to the method is limited to forming the basic cone structure comprising a shell 11 filled with a confection substance 12 and having an upper top or freestanding head 13 and the central flavor core 17. Application of the interior coating 16 may be accomplished by a spray process, which is known in the art and therefore not shown or further described. The exterior layer of chocolate 14 and the nuts 15 may be accomplished by using the apparatus as shown in Patent No. 3,580,188. The application of the interior coating 16 is accomplished prior to employment of the method of this invention as described hereinafter, whereas the application of the chocolate layer 14 and the nuts 15 is accomplished subsequent to the formation of the confection with central flavor core. The first step of the method for forming the frozen confection consists of filling the shell 11 with the frozen confection 12 and providing a sufficient further quantity of the confection to the top to form the freestanding head 13. Filling the shell and forming the freestanding head 13 are accomplished through, causing the frozen confection to flow through a discharge tube or nozzle 20 into the open mouth of the shell. While only one nozzle and one shell are shown, it will be understood that a plurality of the shells would be concurrently processed by the automated mechanism for forming the ice cream cones as is shown in the referenced patent with the dispensing assembly having a plurality of nozzles for concurrent filling of a same numbered plurality of pastry shells 11. In Figure 3, the shell and discharge nozzle 20 are shown with a terminal end 21 of the nozzle projected a short distance into the open mouth of the shell. At the beginning of a filling operation or cycle, the nozzle 20 would be at a position with the terminal end 21 spaced a distance above the top end of the shell and the flow of Ice cream initiated. The apparatus is then operated to project the nozzle downward into the shell to a lowermost position as is shown in Figure 3. The column of ice cream flowing downward from the nozzle is projected into the shell where it will be urged into the lower end of the conical shell and in the region that is of a larger cross-sectional area than that of the column of ice cream as it flows from the nozzle, the ice cream will be urged to flow radially outward to fill the shell. After being projected into the shell, the apparatus is operated to withdraw the nozzle 20 from the shell and return it to the relatively elevated position above the shell. The rate of movement of the nozzle in an upward direction is less than the flow rate of the ice cream, resulting in the ice cream's continuing to flow in a radially outward direction. These relative rates of nozzle movement and ice cream flow are adjusted and controlled with consideration to the viscosity of the ice cream so that a generally cylindrical column of ice cream is formed having a diameter substantially equal to the diameter of the open mouth of the shell as shown in Figure 4, thus forming the freestanding head 13. At a predetermined point, when a sufficient quantity of the confection has been discharged to form the head 13, the flow of confection is interrupted and the nozzle is moved abruptly upward to effect a separation of the columns of confection that are in the discharge nozzle and form the head 13. During the step of filling the shell 11 with the frozen confection, such as ice cream, that confection is maintained at a ■ temperature in the range of 17-23 degrees Fahrenheit. In that temperature range, ice cream is of a viscosity that'enables it to flow and to be pumped through the interconnecting conduits and passages of the apparatus. At that temperature, the ice cream is readily capable of conforming to the interior of the shell 11 and will essentially fill the shell, which is of a conical shape. The second step of this method of forming the frozen confection of this invention consists of forming the central flavor core 17 by means of injection apparatus. This injection apparatus is diagrammatically illustrated in Figures 5 and 6 only of the drawings, as other components of a typical injection system of this nature that may be used in forming the frozen confection of this invention are known to those skilled in this art. The relevant portion of a typical injection apparatus comprises an elongated, hollow tube or quill 22 that is open at its lower terminal end 23. This hollow tube is connected through suitable conduits and passages (not shown) to a flow-inducing pump system, which also is not shown. This system's apparatus is operated to pump or cause the flavor substance to flow through the injection quill or tube 22 and to be discharged from its terminal end 23. As in the case of filling the shell with the frozen confection, a number of quills may be connected with a suitable manifold system to provide multiple paths and concurrently to inject the flavor substance into a plurality of the cones filled with the ice cream confection. The quill 22 is also advantageously mounted on an actuating apparatus, which may be similar to that of the discharge nozzle 20 for the confection substance, and is first operated to project the quill downward in central alignment with the vertical axis of the pastry shell 11 to a lowermost position where its terminal end 23 is disposed a predetermined distance above the extreme bottom of the shell and the confection substance that is disposed therein. The interior diameter of the quill 22 for a typical dimension pastry shell is approximately 1/4 inch, and thus with the combined wall thickness, the outer diameter results in the necessity for limiting the downward projection of the quill. This is necessary to avoid overly compressing the confection substance in the lower end portion of the shell and perhaps causing the shell to break. In an illustrative embodiment where the pastry shell 11 has a typical length of four and one-fourth (41/4) inches and a mouth diameter of the order of two (2) inches, a quill of the indicated diameter would be projected to about two-thirds (2/3) of shell length. Once inserted to the position as indicated, the flow-inducing mechanism is operated to cause the flavor substance to begin flowing through the quill 22. Also at this point in the cycle, the mechanism is operated to begin upward movement and withdrawal of the quill from the confection substance with withdrawal being at a rate substantially commensurate with the inflow of the flavor substance. This combined withdrawal of the quill and inflow of flavor substance result in the formation of a vertical column of the flavor substance as is diagrammatically indicated in Figure 6, having a generally cylindrical columnar shape with an irregular surface configuration. Once the quill has reached the upper end of the head, it is abruptly separated to break the column of flavor substance. The mechanism is also operated to terminate the flow of the substance until the quill is inserted in the next succeeding cone to be processed. Since the quill 22 is of a finite size, it will physically displace the confection in the shell and the top T when inserted as shown in Figure 5. To the extent that the confection within the shell 11 is not compressed, insertion of the quill tends to displace the confection upward into the top. This displaced confection also contributes to growth of the top, which is not restrained against radial outward expansion. Consequently, the top will experience a radially outward growth tending to distort the more cylindrical configuration of the top as shown in Figure 4 and produce a more generally spherical shape. Also contributing to this radially outward growth is the transfer of heat from the flavor substance to the confection causing the confection to soften slightly and thereby to have a greater tendency to flow radially outward. A flavor substance, such as caramel, is maintained at a nominal temperature of 40 degrees Fahrenheit, whereas an ice cream confection is maintained at a temperature in the range of 17-23 degrees Fahrenheit. As a consequence of this temperature differential, there will be a heat transfer tending to soften the confection and render it more flowable. The flavor substance at this temperature and in a flowable state is not capable of supporting itself and must depend upon the confection to provide the necessary lateral support for maintaining that portion of the flavor core in a generally columnar configuration. A flavor substance, such as caramel, is normally maintained at a temperature of 40 degrees Fahrenheit so that it will have a viscosity that will enable it to be pumped through a system of this nature. A consequence of this relatively high temperature of the flavor substance is that the temperature differential will result in a fairly rapid warming of the ice cream in the vicinity of the flavor substance with the ice cream's viscosity lowering, and if the ice cream is not subjected to a rapid cooling operation to freeze the substances hard, the freestanding head T would tend to flatten and perhaps flow over the side of the shell along with, the flavor substance 17. However, while the ice cream is at a sufficiently low temperature, it is capable of maintaining its structural configuration to a required degree, and it also functions to support the column of flavor substance that extends through the head or top. It will be noted by reference to Figure 6 that the column of flavor substance has an irregular configuration resulting from the fact that it is flowable and has a specific gravity of approximately 1.3, as contrasted to the specific gravity of ice cream, which is 0.5. Because the flavor substance is relatively heavy, it outweighs the ice cream and will attempt not only to melt the ice cream, but will apply the downward or outward force to distort the standing head. Accordingly, once the core 17 has been formed, the composite article is subjected to a cooling operation to lower the temperatures to a point where the ice cream will be hard-frozen, and the flavor core viscosity will be lowered so that it will become sufficiently viscous to maintain its columnar configuration. During the time of injection of the flavor substance and the interval prior to hardening of the confection and flavor substance to a sufficiently solid state to maintain the configuration, the flavor substance may tend to flow downward within the confection as well as radially outward. This migration of the flavor substance results in the irregular surface of the core 17. Also, the flavor substance tends to migrate downward from the lowermost point at which it is discharged from the quill, the point shown in Figure 5, thereby resulting in a downward extension of the core. Being in a flowable state at the time of discharge, the flavor substance also tends to recede into the confection in the extreme top region of the confection compressing the top T as is illustrated in Figure 6. There is an accompanying tendency for the confection to fill in and over the upper end of the core. Alternative apparatus for practice of the method in forming the" article of this invention is illustrated in Figures 7 and 8. This apparatus comprises a coaxial tube-type dispensing assembly 30. This apparatus, which comprises a structure known to those skilled in this art, includes a pair of elongated tubes 31 and 32 disposed in coaxial alignment with each having a terminal discharge end 33 and 34, respectively. The larger diameter tube 31 is adapted to be connected in flow-communicating relationship with a source of the ice cream or confection substance as through an interconnecting conduit 35. The central smaller diameter tube 32 is adapted to be connected to a source of the flavor substance, such as a caramel, with this tube being supported within the larger tube 31 by a suitable structural support and seal 36. As previously described, with reference to the two-step method, each of the substances is maintained at the preferred temperature or in the preferred temperature range to obtain a viscosity that will enable each substance to be pumped through its respective conduit system and caused to flow into the pastry shell 11. Again, a plurality of the coaxial dispensing assemblies 30 may be connected into a common system for concurrent operation in simultaneously filling a same plurality of pastry shells. In operation of the coaxial tube type dispensing apparatus, the mechanism is displaced into association with a shell 11, and the respective substances are then caused to flow through the system and discharged from the terminal ends 33 and 34 of respective tubes. A filling operation is diagrammatically illustrated in its initial stages in Figure 7 with the assembly 30 having been displaced to its lowermost position with the marginal end portions extending into the upper end portion of the shell as is shown in Figure 7. The small tube 32 for the flavor substance projects a short distance, about one- ourth (1/4) inch, below the bottom end of the large tube 31 from which the confection is dispensed. With this method and its associated apparatus, the flow of the ice cream confection and the flavor substance, which is continuous and concurrent, results in the flavor substance being formed as a columnar core extending completely to the bottom of the conical pastry shell C. With the flow of confection and flavor substances being continuous, a coaxial column of the two substances will be developing in depending relationship to the terminal ends 33 and 34 while the assembly 30 is being lowered and projected into the shell 11. This free, suspended column of the substances is thus urged into engagement with the interior walls of the shell 11 to which the ice cream confection will conform as a consequence of its flowable consistency. Through appropriate adjustment of the flow rates of the respective ice cream confection and flavor substances, a column of flavor substance having a nominal diameter of one-fourth (1/4) inch is dispensed centrally throughout the entire vertical extent of the ice cream. After the assembly 30 is projected into the shell 11 to the point shown in Figure 7, the apparatus operates to elevate the assembly which, after it leaves the shell, forms the freestanding head or top T. When the top is formed to a predetermined height above the shell 11, the assembly 30 is abruptly displaced to its uppermost position shown in Figure 8, resulting in separation of the columns of confection and flavor substance from the assembly and the freestanding head. The column of flavor substance in employment of this method also obtains an irregular configuration as a consequence of the relative temperatures and the tendency of the flavor substance, such as a caramel, to settle and flow radially outward in an attempt to escape and seek a lower level. However, by maintaining the temperature of the ice cream confection in the proper range, the ice cream will be of sufficient viscosity to maintain its general shape and to support the column of the flavor substance that extends through the freestanding head, although there will be a tendency for the head to take a generally spherical shape. When the composite confection is formed, it is placed in a cooling apparatus to lower the temperature of the substances so that each will be hardened sufficiently to maintain its respective configuration. It was previously indicated that the core of flavor substance has a nominal diameter of approximately one-fourth (1/4) inch. The diameter of the freestanding head 13 of a conventionally dimensioned frozen confection of this type approximates two and one-fourth (2 1/4) inches. Attempting to form the core with a relatively larger diameter, such as one greater than one-half (1/2) inch, will be expected to fail because the quantity of flavor substance at a relatively higher temperature will add heat at a rate that will cause the ice cream confection to melt and to be unable to support the column of the flavor substance prior to the time that it could be placed in a cooling apparatus and sufficiently hardened. A one-fourth (1/4) inch diameter column of flavor substance is deemed of sufficient size to provide adequate flavoring. It will also be understood that increasing the size of the flavor substance from one-fourth (1/4) inch will also add to the cost of the confection, although it may be desired to have a greater amount of the flavor substance. After the confection and flavor core combination has been formed by the described method, the composite structure is subjected to further coating operations to apply the chocolate layer 14 and the nuts 15 as may be desired. The frozen confection of this invention as previously described comprised a composite structure of an ice cream confection filling 17. A pastry shell 11 formed a container for the confection and a single, centrally located, vertical core 17 of an appropriate flavor substance. The method, accordingly, as previously described and illustrated, was also related to the techniques of forming a single central core of the flavor substance in the ice cream confection. It is contemplated and is also within the scope of this invention to form a confection having a flavor substance added and incorporated in substantially the same manner, but formed in a plurality of vertical columns. Apparatus for forming a plurality of the flavor substance columns is diagrammatically illustrated in Figures 9-12 with one of the objectives of forming the plural columns being to have the flavor substance dispersed to a certain degree in the ice cream confection rather than having a single column. Another objective to be achieved by forming of a plurality of flavor-substance columns is that it is then possible to provide a plurality of flavor substances in a single frozen confection of this type. Formation of a confection of this type using the quill-injection technique similar to that of Figures 3-6 is diagrammatically illustrated in Figures 9 and 10. Since it is only the quill-injection aspect of the method that is relevant to an understanding of this alternative forming, reference may be had to Figures 3 and 4 of the drawings and the related portions of the specification to understand the aspect of the method related to filling the edible pastry shell 11 with a frozen confection 12, such as ice cream. That first step of the procedure is effected in the same manner and may be accomplished with the same type of apparatus forming a filled shell 11 having a substantially spherically shaped top or freestanding head 13 formed of the frozen confection. It is the second step of that injection technique that is diagrammatically illustrated in Figures 9 and 10. The quill-injection apparatus in this instance includes a plurality of elongated, relatively small-diameter, hollow tubes 40, 41 and 42 disposed in spaced, parallel relationship and supported in a vertically oriented position for insertion axially into the frozen confection 12 contained in the shell 11. These tubes 40, 41 and 42 may be mechanically secured into a mounting bracket 43 which, in turn, is assembled with the apparatus for effecting the vertical displacement of the hollow tubes. The apparatus for effecting vertical displacement of the tubes may be similar to that shown and described in Patent No. 3,580,188 for use with the confection-dispensing apparatus. Each of the tubes 40, 41 and 42 will be understood to be interconnected with a source of the flavor substance with that source being capable of pumping the material through the relatively small-diameter tubes. Each of the three tubes may be connected to a single source or, as previously indicated, each could be connected to its own respective source of a particular flavor to obtain a multiple-flavor confection. The three tubes 40, 41, and 42 may be relatively positioned advantageously in a triangular configuration such as can be best seen in Figure 10. In this respect, it will be noted that Figure 9 is not a true medial sectional view in that the ice cream confection 12 is not shown in the region of the tubes in order that each of those tubes may be seen performing the column-forming function. The tubes in an illustrative embodiment are fabricated from a suitable material having an internal diameter of the order of 0.08 inches and of a relatively thin-wall construction, such that the outer diameter may be of the order of 0.13 inches. The three tubes are located in relatively close proximity to each other in a triangular configuration and are advantageously located within the confines of a circle of one-half (1/2) inch diameter. This physical dimensioning is found advantageous in that it retains the flavor substance within a small area of the center of the ice cream confection for the same reasons discussed with respect to the single-column techniques. Displacing the small columns of flavor substance in a greater area will tend to reduce the capability of the apparatus and method to form the confection so that the freestanding head 13 will maintain its general spherical configuration and be capable of supporting the columns of the flavor substance until such time as they are subjected to the relatively lower temperatures for hardening the confection and effectively solidifying the flavor substance so that they will subsequently maintain their configuration for storage and transport until such time as they are consumed. In Figure 9, the quill-injection apparatus comprising the hollow tubes 40, 41 and 42 is shown at a relative vertical position where the tubes have been partially elevated from their lowermost position. Streams of the flavor substance have been caused to flow through the respective tubes and have been discharged from the respective terminal ends 44, 45 and 46 to form the flavor cores 47, 48 and 49. It will be seen that as with the larger-diameter core 17, these smaller-diameter flavor cores also have an irregular surface configuration resulting from the fact that the flavor substance is of a viscosity to be flowable and its greater weight as compared to the ice cream confection results in lateral flowing of the flavor substance. Additionally, the flavor substance will tend to flow a distance slightly downward with respect to the lowermost point at which the discharge of the substance is initiated. Operation of the multiple-quill apparatus as shown in Figure 9 is essentially the same as that described with the single-quill with the quills being withdrawn at a predetermined rate with respect to the flow of the flavor substance to form the respective cores 47, 48 and 49 of the flavor substance. Again, as the terminal ends 44, 45 and 46 of the tubes reach the upper end of the head 13, the apparatus is operated to separate the quills abruptly and to break and separate the columns of flavor substance. A coaxial tube-type dispensing apparatus 50 for forming a plurality of flavor cores of flavor substance in a confection of this type is diagrammatically illustrated in Figures 11 and 12. This apparatus is similar in construction and functioning to that described and illustrated in Figures 7 and 8. The apparatus includes a large-diameter outer tube 51 having a terminal discharge end 52. This tube 51 is of a diameter such that it can be projected a short distance interiorly of the open upper mouth of the pastry shell 11. The interior of this tube 51 is connected to a source of frozen confection, such as ice cream, by means of a conduit system, diagrammatically illustrated at 53. This dispensing apparatus 50 would be supported on the apparatus for filling of the shells 11 similar to that illustrated in Patent No. 3,580,188 and is adapted for vertical reciprocation of the dispensing apparatus. Extending axially through the tube 51 are a plurality of relatively small-diameter, hollow tubes 54, 55 and 56 disposed in spaced, parallel relationship and arranged in a triangular configuration best seen in Figure 12. Again, as in the case of Figure 9, the diagrams are not true medial sectional views in that the ice cream confection is not shown in the vicinity of the tubes in Figure 11 so that the tubes may be more clearly seen as is also true with the columns of flavor substance that are being formed. The small-diameter tubes extend axially through the center of the larger tube 51 and are supported at the upper end of that tube by a suitable structural support and seal 57, which closes the upper end of the larger outer tube 51 and maintains the small tubes in suspended relationship. Each of the smaller tubes is also understood to be connected to a suitable source of flavor substance that can be operated to pump that substance in a flowable state through the small-diameter tubes. These tubes are of the same dimensional characteristics of those described in conjunction with Figure 9. It will also be understood that each of the tubes 54, 55 and 56 may be either connected to the same source of flavor substance or to each of different respective flavor substance sources. The small-diameter hollow tubes 54, 55 and 56 extend a distance downward through the outer tube 51 with their terminal ends 58, 59 and 60 being displaced a distance upward from the terminal end 52 of the outer tube, but being at a location that is downstream from the entrance of the ice cream confection through the conduit system 53. In this coextrusion-type apparatus, the ice cream confection and flavor substances are caused to flow continuously and the flavor substance enters into the flowing stream of ice cream at a point where the flow paths will not be significantly disturbed and the streams of the flavor substance will remain separate and form their respective vertically extending cores 61, 62 and 63. In Figure 11, the dispensing apparatus 50 is shown at its lowermost position where the shell 11 is first substantially filled before the dispensing apparatus is vertically displaced to form the freestanding head in a manner that is essentially the same as described in conjunction with Figure 8. In describing the formation of the flavor cores by the method of this invention, it was noted that with the flavor substance being at a predetermined temperature such that it can be caused to flow through either the quills in the injection technique or the tubes in the coextrusion technique, the flavor substance has a tendency to flow or migrate radially outward. Although this characteristic of the flavor substance results in flavor- cores having irregular surface configurations, the flavor cores are shown as having a nominal diameter that is substantially equal to the inside diameter of the tubes from which they are extruded or discharged. This dimensional control is effected through control of the rate of flow of the flavor substance with respect to either the rate of withdrawal of the quills in the injection technique or the rate of flow of the confection in the coextrusion technique. When the rates are equal, the core diameters will be equal to the tube diameters. However, if desired, the nominal core diameters may be increased or decreased by a proportional change in the relative rates of flow or displacement. It is to ' be understood that while the drawings illustrate forming of three flavor cores, the number can be two or four or such ' other number as may be practical with due consideration to the characteristics of the particular confection or flavor substances and apparatus-operating parameters. From the foregoing description of an illustrative embodiment of a frozen confection having a freestanding head and a flavor core and the method of forming, it will be readily seen that an improved confection product is provided. The inventive method enables the formation of this novel confection having a central core of a flavor substance extending substantially throughout the vertical extent of the confection, such as ice cream.

Claims: WHAT IS CLAIMED IS: 1. The method of producing an individual serving of a frozen confection having an open top, edible-shell container filled with an ice cream and a central axial core of a flavor substance, including the steps of: (1) filing the container with an ice cream having a temperature at which the viscosity of the ice cream is such that the ice cream may be caused to flow from an orifice of a dispensing apparatus into the container, and is sufficiently viscous to retain an unsupported shape; (2) forming an integral head of ice cream extending above the open top of the container; (3) forming an axially extending core of a flavor substance centrally in the ice cream by introducing said flavor substance into the ice cream at a temperature that is above the melting temperature of the ice cream and the viscosity of the flavor substance is such that it may be caused to flow from an orifice of a dispensing apparatus; (4) maintaining the introduction of said flavor substance substantially throughout the length of said ice cream to form an axial core within the ice cream extending from the bottom of the container through the freestanding top of the ice cream; and (5) lowering the temperature of the composite formed from the ice cream and the flavor substance such that the ice cream becomes frozen and the flavor substance becomes sufficiently viscous so as to maintain a columnar configuration axially within the ice cream. 2. The method of claim 1 in which step of forming the head includes forming a ball-shaped head extending above the container. 3. The. method of claim 1 in which the edible shell is a pastry having a cone shape and a circular cross-section, in which method the steps of filling and forming comprise a step of coaxial extrusion. 4. The method of claim 1 in which the step of filling includes filling the container with sufficient ice cream such that the ice cream volume conforms to the interior volume of the container. 5. The method of claim 1 or claim 2 or claim 3 or claim 4 in which the step of forming the core of a flavor substance includes forming a central core of the flavor substance surrounded by ice cream in which the flavor substance introduced forms a core having a nominal diameter of about one-eighth to one-fourth of the diameter of the open top of the shell container. 6. The method of claim 5 in which the flavor substance is caramel and the step of forming includes introducing the caramel at a temperature of about 40 degrees Fahrenheit. 7. The method of claim 5 in which the step of forming includes introducing the flavor substance beginning at the bottom of the container. 8. The method of claim 5 in which the step of forming includes forming a plurality of flavor-substance columns within a cross-section of the ice cream in an essentially axial relationship with respect to a centerline longitudinally traversing the volume of ice cream.

Inventors: HEINRICH DAVID B, SUTTON DAVID M, HEINRICH, DAVID, B., SUTTON, DAVID, M.
Applicants: DRUMSTICK CO, DRUMSTICK COMPANY
Application year: 1987
Main classification: A23G9
IPC codes: A23G9