Abstract:
An ear of corn attached to a power driver such as a drill can be husked and or creamed in a two-step process without detaching the ear from the driver. The shelling device uses a spring-biased grater inside a tube to cut the kernels from the cob, and may be used alone or in combination with the husking device. If desired, the two devices can be connected using an ergonomically designed bracket and used sequentially.

Description:
BACKGROUND OF INVENTION  
   This invention is in the general field of grain processing, more particularly as it relates to removing the edible portion of the grain from the inedible portion after harvesting. Still more particularly it relates to devices and methods for removing husks from ears of corn and removing corn kernels from the cobs, especially such devices and methods which are power-driven.  
   Prior art in this field includes generally two separate devices or methods; one for removing the corn husk and silk from the corn ears (“husking”) and another for removing the kernels from the cob. The latter process is generally referred to as “shelling” or “stripping”, and involves a greater or lesser degree of piercing of the kernel wall depending on how the kernel is separated from the cob.  
   Husking of the corn ear is a mechanical process in which the husk is pulled or brushed from the ear. The husk can be pulled downward from the free end of the ear and torn off at the butt by grasping the leaves manually, or it can be brushed or rubbed off with toothed, bristled, or abrasive surfaces or simple frictional contact with certain surfaces. Special additional means may be included to brush or pick the silk from the ear after the husk is removed.  
   Shelling of the corn is generally also a mechanical process in which the kernels are cut or scraped off the cob. If whole kernel corn is desired, it is necessary to detach each kernel from the cob at or near its point of attachment to the cob without puncturing the kernel wall. This may be accomplished with a knife blade applied at the base of the kernels and moved parallel to the longitudinal axis of the ear.   
   If the kernel wall is ruptured extensively during the shelling process, a substantial amount of the paste, or cream, within is released along with the kernels. This mixture is creamed corn, produced to a greater or lesser extent depending on the degree of kernel rupturing. Some creaming occurs when the corn is shelled by scraping the tops of the kernels first and moving downward toward the cob. The degree of rupture of the kernel walls is affected by the speed and direction of scraping and the shape of the scraping implement. In this patent specification, the process of removing the kernel material from the ear, regardless of degree, is referred to as “shelling”.  
   Finally, the kernel material, cobs and husks are typically handled separately for further processing whether it be by hand or by machine.  
   SUMMARY OF INVENTION  
   In one embodiment, this invention provides a new apparatus for shelling or creaming corn using a power driver such as an electric drill. In another, preferred, embodiment, it provides an apparatus and method in which corn ears can be efficiently both husked and shelled in sequence and in tandem, one-by-one, using a power driver. To use either embodiment, a special mandrel is first affixed to an electric drill. Then the mandrel is screwed into the bottom end of an ear of corn that has been debutted. The mandrel with an unhusked corn ear thus affixed and revolved by the drill can then be husked by inserting the ear into the husking portion of the invention. The husking portion is configured to efficiently remove and dispose of both the husk and the corn silk. A husked ear can be shelled or creamed by inserting a husked ear, again on the revolving mandrel, into the shelling portion of the invention. This portion is configured to efficiently remove the kernel material from the cob.  
   It is an object of this invention to provide an apparatus and method that increases the speed, ease, and efficiency of husking, shelling or creaming corn compared with existing methods. It is an object of the invention specifically to improve the efficiency of corn silk removal and recovery of desirable food. It is a further object of this invention to provide these features in a single portable and inexpensive device. Still another object of the invention is to provide an apparatus for husking, shelling or creaming corn that is comprised of few parts and can be cleaned and maintained easily.   

   
     BRIEF DESCRIPTION OF DRAWINGS  
       FIG. 1  is a perspective view of the preferred embodiment of the invented apparatus.  
       FIG. 2  is a side view of the preferred embodiment.  
       FIG. 3  is a side view of the preferred embodiment secured to a table top.  
       FIG. 4  is a front view of the husking tube of the preferred embodiment.  
       FIG. 5  is an exploded view of the husking tube.  
       FIG. 6  is a perspective view of the special mandrel of the preferred embodiment in exploded relation to an ear of corn and an electric drill used as a driver.  
       FIG. 7  is a perspective view of the preferred embodiment being used to husk an ear of corn.  
       FIG. 8  is a front view of the shelling tube of the preferred embodiment. This tube, as configured here, if taken by itself is a distinct embodiment of the invention.  
       FIG. 9  is a view of the shelling tube looking straight down the tube to reveal detail.  
       FIG. 10  is an exploded view of the shelling tube.  
       FIG. 11  is a view of the shelling tube showing fit of a husked ear of corn in it.  
       FIG. 12  is a perspective view of the preferred embodiment being used to cream and remove kernels from the cob.  
   

   DETAILED DESCRIPTION  
   Referring now in greater detail to the drawings, in which like elements are referred to by like reference numerals in each figure,  FIG. 1  is a perspective view of the preferred embodiment of the invented apparatus. It shows a lower husking tube  101  and an upper shelling tube  102  connected by a mounting bracket  103 . The two tubes are comprised of open-ended cylinders, and the mounting bracket is a shaped flat bar. In the preferred embodiment of the invention, the mounting bracket is rigid metal  with a hole  104  near its midpoint to enable fastening to a stationary object (not shown). In the preferred embodiment, the cylindrical parts are formed from thermoplastic pipe. The invented method comprises setting up an ear of corn on a power driver (not shown), inserting a revolving ear of corn first in the husking tube  101 , and then inserting it in the shelling tube  102 .  
     FIG. 2  is a side view of the preferred embodiment, showing that the bracket  103  in this embodiment can be fastened to the two tubes using two conventional fasteners  201  each. The bracket is bent so as to align the tubes nearly parallel and create a horizontal section  202 .  
     FIG. 3  is a side view of the preferred embodiment secured to a table top  301  by a stud  302  and a wing nut  303 . Note that when the apparatus is so affixed, the axes of the tubes are oriented by the bracket  103  to converge at a point to the upper right of the Figure (arrow A). This is so that the user can conveniently access the upper end of either tube with a minimum of motion.  
     FIG. 4  is a front view of the husking tube  101  of the preferred embodiment. It comprises a flat, stiff-bristled brush  401  fastened to the inner wall of the tube by a screw  402  so that the bristles of the brush  401  face the center of the tube. In this view the brush  401  is fastened at its midpoint to the top of the tube  101 , but other orientations of the brush relative to the tube may be used effectively within the scope of this invention. Also visible in this view is one of the two bracket mounting holes  403 .  
     FIG. 5  is an exploded view of the husking tube  101  showing how this portion of the preferred embodiment is assembled. Screw  402  is passed through hole  501  and screwed into the upper surface  502  of the brush  401 .  
     FIG. 6  is a perspective view of the special mandrel  601  of the preferred embodiment in exploded relation to an ear of corn  602  and an electric drill  603  used as a driver. To use this invention effectively, it is necessary to secure the ear to the drill so that the ear is coaxial with the axis of the drill chuck  604  and rotates in fixed relation to the chuck. In the preferred embodiment, the mandrel  601  consists of a headless lag screw  605  with a collar  606  permanently fixed perpendicularly to it at the  bottom  607  of the lag portion  608  of the screw. The lag portion  608  of the screw provides a shank by which the drill chuck  604  can grip the mandrel  601 . To establish the correct alignment of the ear and the drill, the ear is first “debutted” by cutting the stem  609  off the ear at more-or-less right angles to the axis of the ear, producing a flat end  610 . The mandrel  601  is secured then to the drill chuck  604 , and the mandrel is screwed into the end  610  by operation of the drill  603  until the collar  606  comes into contact with the end  610 . The collar  606  helps to assure that the screw will not keep advancing into the corn as it is processed and that the corn will be forced to rotate along with the mandrel.  
     FIG. 7  is a perspective view of the preferred embodiment being used to husk an ear of corn. User  701  turns on the drill  603  and inserts the ear  602  into the husking tube  101 . As the ear enters the tube, it comes into contact with the brush  401 . As the ear  602  revolves against the brush  401 , the husk leaves  702  are brushed from the ear  602  and fall out of the bottom end  703  of the tube  101 . This brushing action to remove the husk has proved by experience to be very efficient, yet not damaging to the kernels. It also effectively removes the corn silk (not shown).  
     FIG. 8  is a front view of the shelling tube  102  of the invention, which together with the bracket and husking tube (not shown) comprises the preferred embodiment of the invention, but by itself comprises an alternate embodiment. The shelling tube  102  comprises a curved cutter head  801  resiliently suspended inside it. In the preferred embodiment of the invented apparatus, the cutter head  801  further comprises a partial cylinder  802  of thermoplastic into which a grater  803  is set. The grater is in this case a piece of sheet metal stamped to as to provide a plurality of triangular points  804 . The grater  803  may be fixed to the partial cylinder by rivets or other means. A portion of the partial cylinder  802  behind the grater  803  may optionally be cut out for ease of cleaning. The cutter head  801  is suspended inside the tube  102  by two spring-biased bolts  806 . The bolts each compress a spring  807  between the inner wall of the tube  102  and the partial cylinder  802 , the compression of which is set by wing nuts  808  (only one shown, the other hidden behind it). Mounting holes  809  for connecting the bracket (not shown) to the tube  102  are shown opposite the cutter head  801 .   
     FIG. 9  is a view of the shelling tube  102  of either embodiment looking straight down the tube to better show the cutting points  804  of the grater  803  protruding towards the center of the tube  102 . Note that the cutting points  804  show as lines here because the creases along which they are bent out by stamping are parallel to axis of the tube  102 . This means that the plane surfaces of the points  804  are parallel to the axis of the tube  102 , so that the widest face of each point is against in the direction of rotation of the corn (not shown). This has significance, as explained further below. Note also that the distance between the grater  803  and the bottom of the shelling tube  102  is at a minimum, represented by distance “d”, due to the extension of spring  807  to the maximum extent allowed by wing nut  808 .  
     FIG. 10  is an exploded view of the shelling tube  102  better showing how the cutter head  801  is assembled into the tube. Grater  803  is affixed to partial cylinder  802  by rivets  805  through rivet holes  1001 . Bolts  806  are passed through cylinder holes  1002 , and springs  807  are placed over the bolts. The assembled head  801  is then set inside tube  102  so that bolts  806  pass through tube holes  1003 . Wing nuts  808  are screwed onto bolts  806 . The assembled shelling tube can then be affixed to the mounting bracket (not shown) through holes  809 .  
     FIG. 11  is a view of the shelling tube  102  of the invented apparatus showing the fit of a husked ear of corn  1101  in it. (Husked ear  1101  is ear  602  after removal of the husk. It is distinct from ear  602  because it presents a corn kernel surface  1102  to grater points  804 .) Typically, a power drill will turn husked ear  1101  clockwise as shown by the arrow, causing kernel surface  1102  to rotate into points  804 . Points  804  will cut and dislodge kernel material as creamed corn particles  1103 . Note that the distance between the grater  803  and the bottom of the shelling tube  102  has been increased to “D” by the presence of husked ear  1101 . Because of the compression of spring  807 , distance “D” will always be whatever the width of husked ear  1101  is, and points  804  will be maintained in contact with the kernel surface  1102 . Thus, shelling of the corn will always occur without the user having to press the husked ear  1101  against the grater  803 . Any pressure applied by the user other than in the axial direction (into the paper) runs the risk of twisting the ear in the mandrel, causing uneven or incomplete shelling of the ear, or inclusion of cob material in the product. With this invention, all the user has to do to shell the corn is insert the ear into the  tube while the drill rotates the ear. Wing nut  808  can be adjusted to a) set the minimum diameter of husked ear that can be shelled, and b) adjust the pressure applied to a typical ear and the consistency of the shelled or creamed corn produced.  
     FIG. 12  is a perspective view of the preferred embodiment of the invented apparatus being used to shell an husked ear of corn. Note that bracket  103  is shaped so that tube  102  is high enough above the table  301  to allow container  1201  to be positioned to catch corn particles  1103 . Alternatively, the invented apparatus could be clamped to the corner of a table so that product and waste could both be collected in containers resting below the table top (not shown).  
   It can be seen by examining  FIGS. 3 ,  6 ,  7  and  12  in sequence that the preferred embodiment can be set up readily and that by using it, complete processing of an ear of corn from having been snapped off the stalk through to creaming of the kernels can be accomplished quickly and ergonomically.