Abstract:
An improved blender or food processor is provided that moves a blade translationally in the vertical plane while another blade or blade assembly rotates in the horizontal plane to stop the blender from cavitating the contents while blending viscous fluids (an air pocket from forming around the cutting blades or forming a vortex or a disruptive vacuum). Both actions of rotating the lower blades and translationally moving the upper blade are done simultaneously using one motor. In a related embodiment, rotational and translational movements are provided with decoupled gear assemblies.

Description:
CLAIM OF PRIORITY 
       [0001]    This application claims priority to and the benefit of a U.S. Provisional Application with Ser. No. 62/293,075, filed on Feb. 9, 2016, which is incorporated herein by reference in its entirety. 
     
    
     FIELD AND BACKGROUND OF THE INVENTION 
       [0002]    The invention relates generally to a food blender or food processor having a jar or jug and rotating blade or blades at the bottom of the jar or jug. 
         [0003]    Most food processors or blenders may process fruit or vegetables or even ice that is placed in the jar or jug and the blades rotated rapidly to convert the food into a slurry or crush the ice finely. Known food blenders have a number of shortcomings including: 1) when food is of a thick consistency and in a large volume it is unable to circulate within the blender jug; 2) food can sometimes make an arch around the blades which results in the blades not having contact with the food and therefore it is not processed and; 3) the center of the blades do not cut the food being processed and as a vortex is formed (visible as a swirl) by rotation of the blades takes the food to the center of the blades the result is that large pieces food and ice are not processed. In some cases a vacuum is formed (or cavitation occurs) in which there is a pocket of air that is getting formed and not all food is being processed or blended. 
       SUMMARY 
       [0004]    There is provided a new blender or food processor concept that moves a blade translationally in the vertical plane while another blade or blade assembly rotates in the horizontal plane and stops the blender from cavitating the contents while blending viscous fluids (an air pocket from forming around the cutting blades (cavitation) or the formation of a vortex or a disruptive vacuum). Both actions of rotating the lower blades and translationally moving the upper blade are done simultaneously using one motor. 
         [0005]    In one example embodiment, a blender blade moves translationally in a vertical plane while a second blade or blade assembly rotates in a horizontal plane, thereby preventing cavitation which leads to inefficient cutting or mixing of ingredients. Both movements are performed using a single motor using a unique gear train and this improvement eliminates that need for stirring sticks or having to open the blender to stir the contents due to the inefficient cutting of prior blenders and food processors. In this example embodiment, the gear train used a spur gear assembly with two helical gears at a 1:1 ratio to drive the rotation and a worm/worm wheel combination to drive the translational movement. In another embodiment, a hypoid gear arrangement is used in place of the spur gear assembly to drive the rotational and translational movement. In a related embodiment, the desired functionality can also be achieved by translationally moving the rotating blade, up and down continuously in an oscillating fashion. Such an action, either by the oscillating rod or oscillating blade assembly, breaks up the vacuum or air pockets created and force the food to be directed back to the blades or the ingredients to be properly mixed. 
         [0006]    In another embodiment, there is provided a food processor having a jar body assembly and a base with a motor drive located within the base, the jar body assembly including a first shaft or rod having a blade assembly disposed on a proximal end, the first shaft having a second shaft disposed therein and adapted to move within the first shaft and protruding from a distal end of the first shaft, the first shaft having a top blade member disposed on an upper distal end spaced above the blade assembly. The food processor also includes a spur gear assembly coupled to the first shaft for axially rotating the first shaft at the proximal end, the spur gear assembly including a first spur gear coupled to the first shaft and a second spur gear coupled laterally to the first spur gear. In addition, the food processor includes a worm gear assembly coupled to the spur gear assembly and to the first shaft, a drive shaft of a worm gear of the worm gear assembly coupled to the second spur gear and a worm wheel gear of the worm gear assembly coupled to a base member of the proximal end of the second shaft to translationally move the second shaft vertically in an oscillating motion, the drive shaft of the worm gear configured to be coupled to and driven by the motor drive in the base. In a related embodiment, the spur gear assembly is comprised of two helical gears having a 1:1 ratio. In another related embodiment, a hypoid gear assembly is coupled to the first shaft for axially rotating the first shaft. In related embodiments, the blade assembly and the top blade member of the food processor are selected from the group consisting of a single blade, a dual blade assembly and a triple blade assembly. 
         [0007]    In yet another embodiment, there is provided a food processor having a jar body assembly and a base with a motor drive located within the base, the jar body assembly including a shaft having a blade assembly disposed on a distal end of the shaft and a base member disposed on a proximal end of the shaft. The food processor further includes a spur gear assembly coupled to the shaft for axially rotating the shaft, the spur gear assembly including a first gear coupled to the shaft and a second gear coupled laterally to the first gear. In addition, the food processor includes a worm gear assembly coupled to the spur gear assembly and to the shaft, a drive shaft of a worm gear of the worm gear assembly coupled to the second gear and a worm wheel gear of the worm gear assembly coupled to the base member of the proximal end of the shaft to translationally move the shaft vertically in an oscillating motion, the drive shaft configured to be coupled to and driven by the motor drive in the base. In a related embodiment, the food processor has a spur gear assembly is comprised of two helical gears having a  1 : 1  ratio. In related embodiments of food processor, the blade assembly and the top blade member are selected from the group consisting of a single blade, a dual blade assembly and a triple blade assembly. 
         [0008]    In yet another example embodiment, there is provided a food processor jar body assembly configured for a food processor system, the food processor system having the jar body assembly and a base with a motor drive located within the base, the jar body assembly including a shaft body and a blade assembly disposed within an upper portion of the jar body assembly, the jar body assembly having a lower portion and a floor separating the upper and lower portions of the jar body assembly, the shaft body having an inner shaft disposed therein with the blade assembly disposed on a distal end of the inner shaft, the inner shaft having a base member disposed on a proximal end of the inner shaft, the base member configured to be engaged with the motor drive and axially rotate the inner shaft independent of the shaft body. The jar body assembly further includes a worm gear assembly disposed within the lower portion of the jar body assembly and located below the floor, the worm gear assembly operatively coupled to the shaft body and configured to translationally move the shaft body vertically in an oscillating motion, the worm gear assembly including a threaded bracket member disposed about the shaft body and at least one worm gear shaft engaged with the threaded bracket member, the at least one worm gear shaft having a worm gear shaft base member disposed on a proximal end of the worm gear shaft, the worm gear shaft base member configured to be engaged with a second motor drive to translationally move the threaded bracket member and the shaft body vertically in an oscillating motion. In one example embodiment, the worm gear assembly includes a second and a third worm gear shaft engaged with the threaded bracket member and the jar body assembly further includes an idler gear assembly disposed within the lower portion of the jar body assembly and configured to engage the first, second and third worm gear shafts in imparting a rotational movement to the worm gear shafts when the first worm gear shaft is engaged with the second motor drive. In this example embodiment, the idler gear assembly includes at least a first idler gear disposed about the first worm gear shaft, a second idler gear disposed about to the second worm gear shaft and a third idler gear disposed about the third worm gear shaft. In a related embodiment, the idler gear assembly includes a fourth idler gear and all of the idler gears are in operative contact with each other in imparting the rotational movement to the worm gear assembly. 
         [0009]    In an embodiment related to the aforementioned embodiment, the food processor jar body assembly further comprises a worm gear assembly support plate configured to support the threaded bracket member and to support the first, second and third worm gear shafts radially about the threaded bracket member. In related embodiments, the food jar body assembly includes at least two electrical limit switches electrically coupled to the second motor and configured to change the direction of translational travel of the shaft body. In related embodiments, the inner shaft base member and the worm gear assembly base member are configured in a ring with external fins disposed radially about the ring structure to facilitate engaging the motor drives. In yet another related embodiment, the food processor jar body assembly further includes a stabilizer bracket disposed about the shaft body and below the blade assembly to engage the floor of the jar body assembly and seal the upper portion of the jar body assembly from the lower portion. In related embodiments, the blade assembly of the food processor jar body is selected from the group consisting of a single blade, a dual blade assembly and a triple blade assembly. 
         [0010]    The invention now will be described more fully hereinafter with reference to the accompanying drawings, which are intended to be read in conjunction with both this summary, the detailed description and any preferred and/or particular embodiments specifically discussed or otherwise disclosed. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only and so that this disclosure will be thorough, complete and will fully convey the full scope of the invention to those skilled in the art. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  illustrates a side translucent view of a food processor jar body assembly with an anti-cavitation blending assembly with an oscillating top blade member within a food processing jar according to the teachings herein; 
           [0012]      FIGS. 2A-2D  illustrate perspective views of an anti-cavitation blending assembly with an oscillating rod with a top blade member along with the various gear assemblies that impart the rotational and translational movement of the top blade member according to the teachings herein; 
           [0013]      FIG. 3  illustrates a side translucent view of a food processor jar body assembly with an anti-cavitation blending assembly with an oscillating blade assembly within a food processing jar according to the teachings herein; 
           [0014]      FIGS. 4A-4C  illustrate perspective views of an anti-cavitation blending assembly with an oscillating blade assembly along with the various gear assemblies that impart the rotational and translational movement of the top blade member according to the teachings herein; 
           [0015]      FIG. 5  illustrates a side translucent view of a food processor jar body assembly with an anti-cavitation blending assembly having combined rotational and oscillating blade movement disposed within upper and lower portions of a food processing jar according to the teachings herein; 
           [0016]      FIGS. 6A-6B  illustrate perspective views of an anti-cavitation blending assembly with the gear assemblies that impart the rotational and translational movement of the shaft body and blade member according to the teachings herein; and 
           [0017]      FIGS. 7A-7B  illustrate side views of an anti-cavitation blending assembly with the gear assemblies that impart the rotational and translational movement of the shaft body and blade member according to the teachings herein. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0018]    Following are more detailed descriptions of various related concepts related to, and embodiments of, methods and apparatus according to the present disclosure. It should be appreciated that various aspects of the subject matter introduced above and discussed in greater detail below may be implemented in any of numerous ways, as the subject matter is not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes. 
         [0019]    The various embodiments of the invention are directed to a new blender or food processor that adds a vertical movement to a rotational blade form factor thereby preventing the user from having to open the pitcher and stir the contents due to cavitation. The blending assemblies described herein automatically pull contents down and into the primary cutting blades and improving the cutting and mixing ability of the device. 
         [0020]    Referring now to the figures,  FIG. 1  illustrates a side translucent view of a food processor assembly  100  with an anti-cavitation blending assembly  110  (supported by a gear support member  106 ; also shown in  FIG. 2D ) with an oscillating rod top blade member  120  within a food processing jar body  102  having a handle  104  according to the teachings herein. Although not shown, various embodiments described herein are configured to operate with a standard food processor base with a motor drive located therein and mechanism for engaging the gear assemblies described hereafter. 
         [0021]    Referring to  FIGS. 2A-2D  there are illustrated views of an anti-cavitation blending assembly  110  with a rod and top blade arrangement  120  and a rotating bottom blade assembly  122 , with an oscillating rod or shaft  121 A including a top blade member  121 B. Blending assembly  110  also includes various gear assemblies  130 ,  140  and  150  that impart the rotational movement of the bottom blade assembly  122  and translational movement of rod  121 A and top blade member  121 B. In this example embodiment, blending assembly  110  includes a shaft  112  having disposed on a distal end bottom blade assembly  122 , where rod or shaft  121 A, oscillates and travels within shaft  112 . Shaft  112  includes a base member  114  disposed on the proximal end where base member  114  is coupled to a worm wheel gear  156  to facilitate translational movement of shaft  112 . In particular, as shown in  FIGS. 2C-2D , there is a pin  157  on a worm wheel gear  156  that fits inside a slot  116  in the base member  114 . As the worm wheel spins or rotates, pin  157  slides in slot  116  and moves base member  114  up and down. Gear assembly  130  includes a spur gear assembly  140  coupled to shaft  112  (in  FIG. 2A ), while shaft  121 A travels within another shaft  112  such that shaft  121 A only travels up and down while shaft  112  is attached to gear  140  and rotates the blade assembly  122  and axially rotates the shaft. Spur gear assembly  140  includes a first gear  142  coupled to shaft  112  and a second gear  144  coupled laterally to first gear  142 . Gear assembly  130  further includes a worm gear assembly  150  coupled to spur gear assembly  140  and to shaft  112 , worm wheel gear assembly  150  including a drive shaft  152  of a worm gear  154  coupled to second gear  144 ; a worm wheel gear  156  of the worm wheel gear assembly is coupled to base member  114  of the proximal end of shaft  112  to translationally move the shaft  121 A vertically in an oscillating motion. In this example embodiment, drive shaft  152  is configured to couple (at a motor attachment ring  116 ) with and be driven by the motor drive in the base of the food processor. 
         [0022]    In this example embodiment, spur gear assembly  140  is comprised of two helical gears  142 ,  144  having a 1:1 gear ratio. In this example embodiment, blade assembly  122  includes a blade  124  with ends that are protruding upwards and a flat blade  126 . During operation, the bottom blade assembly  122  and shaft  121 A rotate within bushing assembly  127 , which acts as a seal to keep blended materials in a pitcher  102  and away from the gear assembly. In any of the blending assemblies described herein, the blade assembly is selected from the group consisting of, but is not limited to, a single blade, a dual blade assembly and a triple blade assembly. In this embodiment, the lower blade assembly rotates and the upper blade member only actuates. In other embodiments, the top upper blade member could actuate and rotate. In other related embodiments, other means to vertically actuate a blade or blade assembly can be used. 
         [0023]    In a related embodiment, a food processor having a jar body and a base with a motor drive located therein includes a shaft having disposed on a distal end a top blade member and a blade assembly disposed on the shaft below and spaced from the top blade member, the shaft having a base member disposed on the proximal end with a gear assembly. In one example embodiment, the food processor includes a hypoid gear assembly coupled to the shaft for axially rotating the shaft, the hypoid gear assembly including a ring gear coupled to the shaft and a pinion gear coupled laterally to the ring gear. In this example embodiment, the processor also includes a worm gear assembly coupled to the hypoid gear assembly and to the shaft, with a worm gear member being disposed on a pinion gear shaft below the pinion gear head and coupled to a worm wheel gear. The worm wheel gear is further coupled to the base member of the proximal end of the shaft to translationally move the shaft vertically in an oscillating motion, the drive shaft configured to be coupled to and be driven by the motor drive in the base. 
         [0024]    Referring now to  FIGS. 3 and 4A-4C ,  FIG. 3  illustrates a side translucent view of a food processor assembly  200  with an anti-cavitation blending assembly  210  (supported by a gear support member  206 ). Blending assembly  210  includes an oscillating blade arrangement  220  located within a food processing jar  202  having a handle  204 .  FIGS. 4A-4C  illustrate views of anti-cavitation blending assembly  210  with various gear assemblies  230 ,  240  and  250  that impart the rotational and translational movement of blade assembly  222 . Blending assembly  210  further includes, in this example embodiment, a shaft  212  having disposed on an upper distal end a blade assembly  220  and a base member  224  disposed on the proximal end that is coupled to a worm wheel gear  256 . Worm wheel  256  has a pin  257  on it that fits in a slot  216  on base member  224 . In this embodiment, shaft  212  does rotate and actuate with the actuation being done by worm wheel  256  and base member  224 , and the rotation being done by spur gear assembly  240 . The distal end of shaft  212  includes a ball bearing holder  215  located within base member  224 , which is considered the linear actuator in most embodiments disclosed herein. Hence, the ball bearing within the holder  215  allows shaft  212  to rotate within base member  224  and member  224  moves the shaft  212  up and down. 
         [0025]    In this example embodiment, gear assembly  230  includes a spur gear assembly  240  coupled to shaft  212  for axially rotating shaft  212 , the spur gear assembly using a first gear  242  coupled to shaft  212  and a second gear  244  coupled laterally to the first gear  242  to implement the rotational movement of the blade assembly. A worm gear assembly  250 , in this example embodiment, is coupled to spur gear assembly  240  and to shaft  212 , with a drive shaft  252  of a worm gear  254  being coupled to second gear  244 . A worm wheel gear  254  is coupled to motor attachment ring member or base member  216  of the proximal end of the shaft to translationally move shaft  212  vertically in an oscillating motion, drive shaft  252  being configured motor attachment ring  216  to be coupled to and driven by the motor drive in the food processor base. In this example embodiment, spur gear assembly  240  is comprised of two helical gears having a 1:1 ratio. 
         [0026]    In this example embodiment, blade assembly  222  includes a blade  224  with ends that are protruding upwards and a flat blade  226  coupled to shaft  212 . During operation, the blade assembly  222  rotates and oscillates and the shaft  212  travels through the bushing assembly  227 , which creates a seal to keep the blended contents in pitcher  202 . In any of the blending assemblies described herein, the blade assembly is selected from the group consisting of, but is not limited to, a single blade, a dual blade assembly and a triple blade assembly. In other related embodiments, other means to vertically actuate a blade or blade assembly can be used. 
         [0027]    Referring now to  FIGS. 5-7B , there is provided another embodiment of a food processor component  300  of a food processing system. In particular,  FIG. 5  illustrates a side translucent view of a food processor jar body assembly  302  with handle  303  that includes within the jar cavity an anti-cavitation blending assembly  310 / 320  having combined rotational and oscillating blade movement disposed within an upper portion  304  of the jar body and a lower portion  305  of the food processing jar body. An advantage of this example embodiment is that jar body assembly  200  facilitates up and down actuation of the blade assembly as it is de-coupled and independent from the motor and blade rotation action. This design uses a large main motor to drive the rotational movement and would require a second, smaller motor for the oscillating movement, which would add a lot more control and reliability as a single set of gears are not subjected to the torque that is provided by the large motor. The center coupling or motor attachment ring  316  on the bottom drives rotation of blade  310  while the coupling off to the side motor ring  326  is what controls the actuation through  3  worm gears forming worm gear assembly  320 . A center bearing assembly or stabilizing bracket  322  is secured to blade shaft body  312  and moves up and down (as the worm gears turn) and spins or rotates as the center drive coupling spins. There are thrust bearings on the top and bottom of the bearing assembly  322  to accommodate the up and down load during actuation. 
         [0028]    In this example embodiment, food processor jar body assembly  300  is a component of a food processor system that along with the jar body  302  has a base with a motor drive located within the base. Jar body assembly  300  includes a shaft body  312  and a blade assembly  310  disposed within an upper portion  304  of jar body  302 , the jar body assembly having a lower portion  305  and a floor  306  separating upper  304  and lower  305  portions of jar body assembly  300 . Shaft body  312  has an inner shaft  315  disposed therein with blade assembly  310  disposed on a distal end of inner shaft  315 . The inner shaft has a base or ring or coupling member  316  disposed on a proximal end of inner shaft  315 , with base or coupling member  316  configured to be engaged with the motor drive (not shown) of the food processor to axially rotate inner shaft  315  independent of shaft body  312 . Jar body assembly  300  further includes a worm gear assembly  320  disposed within the lower portion of the jar body assembly and is located below floor  306 . Worm gear assembly  320  is operatively coupled to shaft body  312  and is configured to translationally move shaft body  312  vertically in an oscillating motion when it is engage with a motor drive. In this example embodiment, worm gear assembly  320  includes a threaded bracket member  322  that is disposed about shaft body  312  and includes at least one worm gear shaft  325  and worm gear  324  that is engaged with the threaded bracket member. Worm gear shaft  325  has a worm gear shaft base member or coupling  326  disposed on a proximal end of worm gear shaft  325 , the worm gear shaft base member or coupling configured to be engaged with a second motor drive (not shown) to translationally move threaded bracket member  322  and shaft body  312  vertically in an oscillating motion. 
         [0029]    In this example embodiment, food processor jar body assembly  300  further includes a worm gear assembly support plate  360  configured to support threaded bracket member  322  and to support worm gear assembly  320  (first, second and third worm gear shafts radially about the threaded bracket member, described later) and an idler gear assembly  340 . In related embodiments, food jar body assembly  300  includes at least two electrical limit switches (not shown) that are electrically coupled to the second motor (not shown) in the base of the food processor system which are used to change the direction of translational travel of shaft body  312 . In related embodiments, the inner shaft base member  316  and the worm gear assembly base member  326  are configured in a ring with external fins disposed radially about the ring structure to facilitate engaging the motor drives in the base of the food processor system. In this example embodiment, the food processor jar body assembly further includes a stabilizer bracket  314  disposed about shaft body  312  and below blade assembly  310  to engage floor  306  of jar body  302  and to seal the upper portion of the jar body assembly from the lower portion. In related embodiments, blade assembly  310  of the food processor jar body assembly is selected from the group consisting of a single blade, a dual blade assembly and a triple blade assembly. 
         [0030]    In one example embodiment, and referring more closely to  FIGS. 6A-7B , worm gear assembly  320  includes a second  327  and a third  329  worm gear engaged with threaded bracket member  322 . Idler gear assembly  340  disposed within the lower portion of the jar body assembly engages first  324 , second  327  and third  329  worm gears in imparting a rotational movement to the worm gear shafts when the first worm gear shaft  325  is engaged with the second motor drive (not shown). In this example embodiment, idler gear assembly  340  includes at least a first idler gear  342  disposed about the first worm gear shaft  325 , a second idler gear  346  disposed about to the second worm gear shaft  328  and a third idler gear  348  disposed about the third worm gear shaft  331 . In this embodiment, idler gear assembly  340  includes a fourth idler gear  344  and a fifth idler gear  350  with all of the idler gears being in operative contact with each other in imparting the rotational movement to worm gear assembly  340  and to threaded bracket member  322 . 
         [0031]    Referring again to  FIGS. 6A-6B  there is illustrated perspective views of raised and lowered configurations of shaft body  312  (showing inner shaft  315  as well) and how threaded bracket member  322  engages the various worm gears. With respect to  FIGS. 7A-7B , there are illustrated side views of lowered configurations of shaft body  312  with respect to the worm gears and to support plate  360 . Note that  FIG. 7B  illustrates the decoupled structure of the rotational aspect driven by member  316  and the translation aspect driven by member  326 . This approach also provides for rotational movement of the blade assembly should the translational movement become inoperative. 
         [0032]    The following patents and publications are incorporated by reference in their entireties: U.S. Pat. Nos. 5,645,346; 6,254,019; 9,049,967 and 9,107,539. 
         [0033]    While the invention has been described above in terms of specific embodiments, it is to be understood that the invention is not limited to these disclosed embodiments. Upon reading the teachings of this disclosure many modifications and other embodiments of the invention will come to mind of those skilled in the art to which this invention pertains, and which are intended to be and are covered by both this disclosure and the appended claims. It is indeed intended that the scope of the invention should be determined by proper interpretation and construction of the appended claims and their legal equivalents, as understood by those of skill in the art relying upon the disclosure in this specification and the attached drawings.