CLAIM OF PRIORITYThe present application represents a divisional application of and claims priority to U.S. patent application Ser. No. 14/508,133 entitled “BLENDER ASSEMBLY”, currently allowed, and further claims priority to and the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 61/895,648, filed Oct. 25, 2013, entitled “MAGNETIC DISK COUPLER WITH MILD STEEL BACKING PLATE,” both of which are hereby incorporated herein by reference in its entirety.
The present concept generally relates to a blending appliance, and more particularly to a blending appliance, wherein a blade assembly disposed within a blending jar is magnetically coupled to a drive system.
One aspect of the present concept includes a blending appliance having a housing including a motor compartment and a jar receiving portion spaced laterally therefrom. The jar receiving portion includes an upper retaining member. A motor is disposed in the motor compartment. A support pad is operably coupled to the housing. A jar includes a lid with a feed chute. The jar and lid are configured for reception in the jar receiving portion. The lid is vertically secured onto the jar by the upper retaining member upon reception of the jar into the jar receiving portion. A blade assembly is disposed within the jar and is magnetically coupled to a drive system disposed within a base portion of the housing. A brake mechanism is coupled to the magnetic coupling assembly to stop the rotation of the blade assembly when the jar is laterally removed from the housing base.
Another aspect of the present concept includes a blending appliance having a housing with a motor compartment and a jar receiving portion spaced laterally therefrom. The housing includes a laterally extending upper housing portion. A motor is disposed in the motor compartment is adapted to drive a blade assembly of the jar through a magnetic coupling system. A jar includes a lid, and the jar and lid are adapted to be laterally received within the jar receiving portion, wherein the lid is vertically secured onto the jar by a lower portion of the upper housing upon reception of the jar into the jar receiving portion.
Another aspect of the present concept includes a blending appliance having a housing which includes a jar receiving area defined between an upper housing and a support base which both laterally extend from a motor compartment. A blender jar includes a base portion and a receptacle portion, and is configured to be laterally received within the jar receiving area of the housing. A magnetic coupling system includes an upper magnetic coupler disposed in the base portion of the blender jar and a lower magnetic coupler disposed in the support base of the housing. The upper and lower magnetic couplers are magnetically coupled to one another using one or more permanent magnets defining upper and lower magnetic arrays respectively. The lower magnetic coupler is also configured to rotate the upper magnetic coupler within the base portion of the blender jar as powered by a motor. A blade assembly is disposed in the receptacle portion of the blender jar, and is also operably coupled to a drive shaft which is further coupled to the upper magnetic coupler. A brake mechanism is disposed on the upper magnetic coupler and is configured to stop rotation of the upper magnetic coupler when the blender jar is removed from the jar receiving area.
Another aspect of the present concept includes a blending appliance having a housing which includes a jar receiving area defined between an upper housing and a support base. A blender jar includes a base portion and a receptacle portion, and is removeably received within the jar receiving area of the housing. An upper magnetic coupler is disposed in the base portion of the blender jar for rotation therein. The upper magnetic coupler is vertically movable between engaged and disengaged positions along a drive shaft. A bearing assembly is disposed about the drive shaft. In assembly, the drive shaft couples the upper magnetic coupler to a blade assembly disposed in the receptacle portion of the blender jar. The bearing assembly further includes a first brake surface. A second brake surface is disposed on the upper magnetic coupler and is configured to contact the first brake surface when the blender jar is removed from the jar receiving area and the upper magnetic coupler is in the engaged position. A lower magnetic coupler is disposed in the support base of the housing for rotation therein. The upper magnetic coupler is magnetically coupled to the lower magnetic coupler for rotation therewith when the upper magnetic coupler is in the disengaged position.
Yet another aspect of the present concept includes a magnetic coupling system for a blending appliance wherein an upper magnetic coupler and a lower magnetic coupler are magnetically coupled using one or more permanent magnets defining upper and lower magnetic arrays. The lower magnetic coupler is configured to rotate the upper magnetic coupler using magnetic torque. A blade assembly is coupled to a drive shaft which is further coupled to the upper magnetic coupler for rotation therewith. A brake mechanism is configured to stop rotation of the upper magnetic coupler when the upper magnetic coupler is in an engaged or braking position.
Yet aspect of the present concept includes a blending appliance having a housing which includes a motor compartment and a jar receiving portion spaced laterally or vertically therefrom. The motor is disposed in the motor compartment and is adapted to drive the blade assembly of the jar through a magnetic coupling system. A magnetic coupling system may include an upper non-magnetic, electrically conductive coupler disposed in the base of the jar and a lower magnetic coupler disposed in a support base of the housing. The upper and lower couplers are magnetically coupled to one another using one or more permanent magnets defining the lower coupler and a copper, copper alloy or other electrically conductive metal defining the upper coupler. The rotating magnetic field of the lower coupler generates inductive eddy currents in the upper coupler thus coupling the upper and lower coupler with magnetic inductance to drive a blending cutter configured within the jar.
These and other aspects, objects, and features of the present concept will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and drawings.
In the drawings:
FIG. 1 is a top perspective view of one embodiment of a low profile side drive blending appliance of the present concept;
FIG. 2 is a top perspective cross-sectional view of the low profile side drive blending appliance ofFIG. 1;
FIG. 3 is a rear perspective cross-sectional view of the low profile side drive blending appliance ofFIG. 1;
FIG. 4 is a top perspective view of another embodiment of a low profile side drive blending appliance;
FIG. 5 is a top perspective view of yet another embodiment of a low profile side drive blending appliance;
FIG. 6 is a side elevational view of yet another embodiment of a low profile side drive blending appliance;
FIG. 7 is a top perspective view of yet another embodiment of a low profile side drive blending appliance;
FIG. 8A is a top perspective exploded view of an upper housing and feed chute assembly;
FIG. 8B is a cross-sectional view of the feed chute assembly ofFIG. 8A as assembled;
FIG. 8C is a cross-sectional view of the feed chute assembly ofFIG. 8B;
FIG. 8D is a cross-sectional perspective view of the feed chute assembly ofFIG. 8B;
FIG. 9 is an top perspective exploded view of a user-interface;
FIG. 10 is an assembled cross-sectional view of the user-interface ofFIG. 9 coupled to an upper housing;
FIG. 11A is a top perspective view of the user-interface ofFIG. 9;
FIG. 11B is a front elevational view of the user-interface ofFIG. 9;
FIG. 12 is a cross-sectional view of a bearing assembly and blade assembly;
FIG. 13 is a top perspective exploded view of the bearing assembly ofFIG. 12;
FIG. 14 is a cross-sectional view of an upper portion of a blender jar, cap and feed chute assembly;
FIG. 15 is a cross-sectional view of an upper portion of a blender jar, cap and interlock switch assembly;
FIG. 16A is a top perspective view of the interlock switch assembly ofFIG. 15 in an “OFF” position;
FIG. 16B is a top perspective view of the interlock switch assembly ofFIG. 15 in an “ON” position;
FIG. 17 is a cross-sectional view of yet another embodiment of a blending appliance;
FIG. 18 is a cross-sectional view of yet another embodiment of a blending appliance;
FIG. 19 is a top perspective view of the blending appliance shown inFIG. 18;
FIG. 20A is a rear perspective view of a base portion of a blender jar;
FIG. 20B is a rear perspective view of another embodiment of a base portion of a blender jar;
FIG. 21 is a top perspective view of another embodiment of a base portion of a blender appliance;
FIG. 22A is a cross-sectional view of a blender jar and blender jar base portion having a magnetic coupler disposed therein;
FIG. 22B is a fragmentary perspective view of the blender jar ofFIG. 22A showing a base portion vent member;
FIG. 22C is a cross-sectional view of the base portion of the blender jar shown inFIG. 22B;
FIG. 23 is a is a cross-sectional view of the blender jar ofFIG. 22A as magnetically coupled to a base portion of a blending appliance, having a magnetic coupler disposed therein;
FIG. 24 is a schematic view of a magnetic loop of a magnetic coupling system;
FIG. 25A is a cross-sectional view of a blender jar and blender jar base portion having a magnetic coupler and a braking system in a disengaged position;
FIG. 25B is a cross-sectional view of the braking system ofFIG. 25A in an engaged position;
FIG. 26 is a cross-sectional view of a blender jar and blender jar base portion having a magnetic coupler and a braking system of another embodiment in a disengaged position;
FIG. 27A is a perspective exploded view of another embodiment of a blender jar and lower collar portion having a heating element;
FIG. 27B is a perspective view of the blender jar and lower collar portion ofFIG. 23A in an assembled view;
FIG. 27C is a cross-sectional view of the blender jar and lower collar portion ofFIG. 23B;
FIG. 27D is a cross-sectional view of the heating element ofFIG. 27A;
FIG. 27E is a rear perspective view of the heating element ofFIG. 27D;
FIG. 28A is a cross-sectional view of another embodiment of a heating element;
FIG. 28B is a cross-sectional view of yet another embodiment of a heating element;
FIG. 29A is a top perspective exploded view of a heating element;
FIG. 29B is a top perspective view of the heating element ofFIG. 29A in an assembled view;
FIG. 29C is a cross-sectional view of yet another embodiment of a heating element;
FIG. 29D is a cross-sectional view of yet another embodiment of a heating element;
FIG. 30 is a top perspective view of a powered upper housing assembly; and
FIG. 31 is a cross-sectional view of yet another embodiment of a blending appliance.
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the concept as oriented inFIG. 1. However, it is to be understood that the concept may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
Referring toFIGS. 1-3,reference numeral10 generally designates a blending appliance having ahousing12 including amotor compartment14 and ajar receiving portion16 spaced laterally therefrom and which defines a cavity. Thejar receiving portion16 includes an upper retainingmember18. Amotor20 is disposed in themotor compartment14. Asupport pad22 is operably coupled to thehousing12. Ajar24 includes alid26 with afeed chute30. Thejar24 andlid26 are configured for reception in thejar receiving portion16. Thelid26 is vertically secured onto thejar24 by the upper retainingmember18 upon reception of thejar24 into thejar receiving portion16.
Referring again toFIGS. 1-3, the illustrated blendingappliance10 is generally configured to include a low profile to easily accommodate use under a cupboard or shelf in a kitchen area. Thejar24 of the blendingappliance10 is designed to engage thehousing12 from a lateral direction. Most traditional blending appliances include a construction that mandates vertical or drop-in placement of a jar onto a base that includes a motor therein. Unfortunately, these constructions require substantial vertical space above the base, and when connected with thejar24, provide for a very tall appliance.
As shown in the illustrated embodiment ofFIG. 1, thehousing12 includes a slightly widenedhousing base40 andsupport pad22 disposed below the upper retainingmember18. The upper retainingmember18 is designed to maintain thelid26 of thejar24 on thejar24 during mixing of food goods inside thejar24. In the illustrated embodiment, the upper retainingmember18 includes anarcuate recess44 configured to receive at least a portion of thefeed chute30 that extends through thelid26. Thefeed chute30 includes aremovable cap46. Theremovable cap46 can be removed from thelid26 to install food goods into thejar24 when thejar24 is in connection with thehousing12. A taperedinternal wall48 is disposed on either side of thearcuate recess44. The taperedinternal wall48 of thehousing12 allows for easy and quick insertion of thejar24 andlid26 into thehousing12, and at the same time, prevents thelid26 from disengaging with the top of thejar24 when the blendingappliance10 is activated. Thesupport pad22 extends from a forward portion of thehousing12 and generally defines a base that supports thejar24 when thejar24 is engaged in the blendingappliance10. The base may include a heating element disposed therein adapted to warm or heat food goods located inside the blendingappliance10.
In addition, thesupport pad22 includes ajar lock60. Thelower jar lock60 is designed to engage ajar base62, such that a bottom of thejar24 does not move away from the housing during activation of the blendingappliance10. It is contemplated that thejar lock60 may be spring-biased to a raised position, such that during insertion of thejar24 into thehousing12, thejar lock60 springs upward to securely engage thejar24 in thehousing12. To remove thejar24, a user would simply push down on the spring-biasedjar lock60 until atop edge64 of thejar lock60 is positioned below a bottom surface of thejar24. After thejar lock60 has been moved to this lowered position, thejar24 can safely be removed laterally from thehousing12.
Referring again toFIG. 1, aslider switch70 is disposed on a side of thehousing12. Theslider switch70 has the effect of controlling the speed of themotor20 disposed inside themotor compartment14 of thehousing12. Theslider switch70, and therefore, the speed control, is generally linear in the illustrated embodiment. However, it is also contemplated that knobs or other electrical or mechanical user interface assemblies may be utilized to control the rate or speed of themotor20, such as the dial configuration described below with reference toFIGS. 9 and 10. In the illustrated embodiment, theslider switch70 is designed to control the motor speed, and consequently, ablade assembly72 inside thejar24 from slow to chop, chop to mix, mix to puree, and puree to liquefy. It is contemplated that theslider switch70 may have incremental activation points, or may include a continuous electrical switch that allows any of an infinite number of motor speeds.
Referring now toFIGS. 2 and 3, the inner componentry of the blendingappliance10 of the illustrated embodiment will be discussed. As illustrated, theblade assembly72 of the blendingappliance10 is fixedly engaged with ajar drive shaft80. Thejar drive shaft80 extends downward through a bottom portion of thejar24 and is sealed by gaskets. The bottom of thejar drive shaft80 is configured to engage agear assembly82 disposed below thejar24. Thegear assembly82 is positioned above thesupport pad22 in agear housing84. In the illustrated embodiment, there are three gears that relay rotational forces from the motor to the blade assembly. However, it is contemplated that more or less gears may be utilized in the blendingappliance10. In addition, it is also contemplated that a belt driven system may be utilized that requires less gears overall. In the illustrated embodiment, ajar drive gear86 is disposed below thejar drive shaft80. Thejar drive gear86 is rotatably engaged with atransition gear88, which is operably engaged with amotor drive gear90. Themotor drive gear90 is fixedly connected with amotor drive shaft92 that extends downwardly from themotor20. Themotor drive shaft92 is supported by adrive shaft bracket94. The entire motor assembly is supported over amotor bracket96 inside themotor compartment14. In the illustrated embodiment, themotor20 includes amagnet98 and a windingassembly100 that is protected by amotor shroud102. Themotor shroud102 protects themotor20 and keeps it free of moisture and debris. Ashroud bracket104 is disposed inside themotor shroud102 and supports afan assembly106 disposed above themotor20. Thefan assembly106 moves air inside themotor compartment14, preventing or minimizing the likelihood of themotor20 overheating.
Referring now toFIG. 4, in another embodiment, a blending appliance140 includes ahousing148 and amotor system150 positioned above ajar152. Thejar152 includes adrive shaft154 that is operably engaged with a vertically extendingauger156 that extends into thejar152 under a lid157 of thejar152. The vertically extendingauger156 is fixedly engaged with ablade assembly158 disposed at the bottom portion of thejar152. The vertically extendingauger156 also includes ahelical flange160 that extends about a portion of the vertically extendingauger156, and which minimizes bridging of food during blending. A top portion of thehousing148 of the blending appliance140 illustrated inFIG. 4 includes alocking tab162 that locks thejar152 and the vertically extendingauger156 in place in connection with thehousing148. In use, a user would insert thejar152 into thehousing148 from a lateral direction. After insertion, thelocking tab162 would be moved to a lower locking position, such that the vertically extendingauger156 is engaged and thejar152 is secured in place in ajar receiving portion166 of thehousing148. At this point, a user is free to operate themotor system150 at any of a variety of speeds as the lid157 of thejar152 is secure on thejar152.
In another embodiment, as illustrated inFIG. 5, a blendingappliance200 includes ajar202 having anauger204 disposed inside thejar202. Thejar202 is configured for engagement with ahousing206 of the blendingappliance200. In this embodiment, thehousing206 includes anengagement member208 that extends forward from atop portion210 of thehousing206 and is configured to receive a top portion of theauger204. Upon reception of the top portion of theauger204, a motor system can be activated, which will subsequently turn theauger204 inside thejar202.
With reference now toFIG. 6, in yet another embodiment, a blendingappliance250 includes ahousing252 with female receivingports254 configured to receivemale extensions256 that protrude from abase258 of a blendingjar260. Themale extensions256 act as power relays configured to activate a heating element disposed in thebase258 of the blendingjar260. Thebase258 of the blendingjar260 can then serve to warm food goods disposed inside the blendingjar260. Controls for a desired temperature of the heating element disposed in the blendingjar260 may be provided on thehousing252 of the blendingappliance250, or on the blendingjar260 itself. This embodiment also includes a top mountedmotor system262 with adrive shaft264 that extends downward into the blendingjar260. Thedrive shaft264 is operably coupled to ablade assembly266.
Referring now toFIG. 7, in yet another embodiment, a blendingappliance300 includes ahousing302 and a blendingjar304 configured for lateral engagement with thehousing302. The blendingjar304 can be fit into ajar receiving portion306 of thehousing302. As the blendingjar304 slides into thejar receiving portion306 of thehousing302, upper andlower drive shafts308,310 that extend from the blendingjar304 engage first andsecond drive assemblies312,314, respectively, in thehousing302. Accordingly, food goods disposed inside the blendingjar304 can be blended by anupper blending assembly316 operably coupled with theupper drive shaft308, as well as alower blending assembly318 operably coupled with thelower drive shaft310. Theupper blending assembly316 includes a plurality ofblades320. Thelower blending assembly318 includes avertical transition gear322 rotatably engaged with ahorizontal drive gear324 that is fixedly coupled with thelower blending assembly318. Controls for operating the upper andlower blending assemblies316,318 can be disposed on either thehousing302 or the blendingjar304.
Referring now toFIGS. 8A-8D,reference numeral400 generally indicates a feed chute assembly for use in conjunction with another embodiment of a blendingappliance10A. As shown inFIG. 8A, the blendingappliance10A includes anupper housing402 having ahousing aperture404 disposed therethrough. Thefeed chute assembly400 includes acap406 which is adapted to closehousing aperture404 in assembly as shown inFIG. 8B. Acup assembly407 is coupled to thecap406 and is adapted to be received in afunnel member408 which includes anupper lip portion409 and abody portion410. Thebody portion410 generally defines acavity412 in which thecup assembly407 is received. Together, thecup assembly407 and funnel408 define a feed chute or pathway P through theupper housing402, which opens into ablender jar24A. Thecup assembly407 includes abody portion413 havingchannels414 that substantially run the length of thebody portion413 of thecup assembly407, such that in assembly, thechannels414 define avent416 between thecup assembly407 and thebody portion410 of thefunnel408. This vented arrangement is best shown inFIGS. 8B and 8C as an arc-shaped vent as further described below.
Referring specifically toFIGS. 8B-8D, a venting path from theblender jar24A through thefeed chute assembly400 is indicated by arrow A. Thefeed chute assembly400 is adapted to vent air from theblender jar24A as air or steam may be forced upwards towards thefeed chute assembly400. This pressure could remove a lid assembly that is not properly ventilated. As best shown inFIG. 8C, thecup assembly407, as received in thefunnel408, forms avent416 disposed along the length of both thecup assembly407 and funnel408. Thecup assembly407 further includesradial clearance apertures418 from which air can vent from theblender jar24A towards thecap406. As shown inFIG. 8B, thebody portion413 of thecup assembly407 is spaced-apart from thebody portion410 of thefunnel408 to define a gap as indicated byreference number417. Thus, air traveling through thevent416 can escape around the periphery of thebody portion413 of thecup assembly407 at thegap417 towards theclearance apertures418. Thus, as shown inFIGS. 8B and 8D, the venting path A forces the air to move vertically throughvent416 and then laterally from thevent416 towards theclearance apertures418. This lateral flow provides for a nonlinear pathway for air to vent from theblender jar24A through thefeed chute assembly400. In this way, vented air, that may be carrying food particles, does not flow directly through thefeed chute assembly400 along a linear vertical path during use. Thecap406 also includes openings orvents420 from which the air can ultimately escape.Openings420 are disposed along a finger well422 which is defined by the coupling of thecap406 andcup assembly407. Thus, thefeed chute assembly400 provides an aesthetically pleasing appearance while allowing venting through thefeed chute assembly400 without any visibly noticeable gaps between mating surfaces. Having clean mating surfaces, thefeed chute assembly400 has less potential for trapping food particles in the system as air is ventilated through thefeed chute assembly400. Further, thecup assembly407 is removable, as shown inFIG. 8A, and can be inverted to define an ingredient measuring cup for use by the user. As shown inFIG. 8D, the interior portion of thebody portion413 of thecup assembly407 includesvolume indicators415 for precise measuring of varying ingredients.
Referring again toFIG. 8D, theupper housing402 includes achannel424 which is comprised of alower portion426 which is generally tapered to frictionally receive thefunnel408 therein. Alanding portion428 is disposed between thelower portion426 and anupper portion430 of thechannel424. Thelanding portion428 houses a twist-inlocking mechanism405 which, as shown inFIG. 8D, engages thecup assembly407, thereby retaining both thecup assembly407 andcap406 in assembly. It is contemplated that thefeed chute assembly400 can couple to theblender jar24A, such that thefeed chute assembly400 can be removed from theupper housing402 and placed in a lid of theblender jar24A as further described below.
Referring now toFIG. 9, auser interface440 is shown in the form of an explodedrotating dial assembly442. Thedial442 generally includes anouter ring444 which is engaged by a user and rotated along a rotational path R1as indicated inFIG. 11B. Theouter ring444 is disposed about acentral aperture446 of thedial442 in which a centralpush button actuator450 is disposed in assembly. Both therotating dial442 andpush button actuator450 may be comprised of a thermoset body portion having a metallic coating. In assembly, thepush button actuator450 remains stationary while therotating dial442 rotates along rotational path R1. The stationary positioning of thepush button actuator450 is generally provided by arotor post452 engaging arotary plate454 through aslot455 disposed thereon. Therotary plate454 is disposed within aretainer456 in assembly. A printed circuit board (PCB)460 is mounted on a central portion of therotary plate454. ThePCB460 includes one ormore LEDs462 and atactile switch464. Aplastic window466 is aligned with theLEDs462 of thePCB460 and is further disposed within thepush button actuator450 in assembly. A biasingspring470 is disposed between thepush button actuator450 and therotary plate454, thereby biasing thepush button actuator450 outwardly in a direction as indicated byarrow472. In this way, thepush button actuator450 can be pushed by a user inwardly in a direction as indicated byarrow474 to activate thetactile switch464 disposed on thePCB460. By engaging and pushing thepush button actuator450, the user makes a selection for a given function as determined by therotating dial442 as further described below.
As further shown inFIG. 9, a plurality offasteners480 are adapted to couple therotary plate454 to a mountingportion447 of therotating dial442. As coupled together, therotating dial442 androtary plate454 are received within aninterior portion457 of theretainer456. As best shown inFIG. 10, theretainer456 is adapted to retain theuser interface assembly440 on a location disposed on theupper housing402 viaclips458 which are resiliently flexible to engage theupper housing402. Amain PCB490 includes apotentiometer492 which is adapted to read an input from theuser interface440 for performing a preselected function of the blendingappliance10A. A plurality offasteners494 are adapted to couple themain PCB490 to theretainer456 via mountingportions459 disposed on theretainer456.
Referring now toFIGS. 11A and 11B, theuser interface440 includes a plurality of functions F which are disposed at discrete locations around therotating dial442. In use, a user will rotate therotating dial442 along the rotational path R1until a selected function F is disposed at a reference point which may be indicated by lighting up the particular function or by using an audible indicator. As shown inFIG. 11B, the functions F may include, but are not limited to, iced drink, soup, milkshake, juice, smoothie, as well as an OFF position, and a progressive blending speed indicator scale identified asreference numeral445. Once the user has rotated thedial442 to the selected function F, the user will push the centralpush button actuator450 to initiate the specific function F. The design of theuser interface440 allows therotating dial442 to rotate a full360 degrees in either direction along the rotational path R1while the centerpush button actuator450 remains stationary. Theuser interface440 is electronically coupled to a controller
Referring now toFIGS. 12 and 13, a bearingassembly500 is coupled to ametal blade assembly501 having a plurality ofblades502. Theblade assembly501 is coupled to ashaft504 by afastener506. Theshaft504 is pressed into and received within first and secondradial bearing assemblies510,512. The first and secondradial bearing assemblies510 and512 are in a vertically stacked configuration and are also separated by aspacer514. The first and secondradial bearing assemblies510 and512 are clearance-fit to a bearinghousing516 defined by the coupling of aretainer member520 and a retainingnut528. Theretainer member520 includes a threadedlower portion522 which engages threaded retainingnut528 in assembly. Theretainer member520 is adapted to be received within a receivingaperture550 disposed within a lower portion ofblender jar24A between thereceptacle portion24C and abase portion62B. Theretainer member520 further includes ahead portion524 which abuts the receivingaperture550 in theblender jar24A in assembly. Thus, theretainer member520 and the retainingnut528 are disposed on opposite sides of the receivingaperture550 in an abutting manner to secure thebearing assembly500 therein. Awave spring532 is a compressible biasing mechanism that abuts aretainer clip530 at an upper end, and further abuts the upperradial bearing assembly510 at a lower end. Thewave spring532 is disposed around theshaft504. Theretainer clip530 is disposed in aninset portion526 within the bearinghousing516 of theretainer member520. Aseal534 is disposed above theretainer clip530 and is configured to seal thebearing assembly500 from contents, such as various ingredients and liquids being processed, disposed in thereceptacle portion24C of theblender jar24A in use. Thewave spring532, abutting theretainer clip530 and thefirst bearing510, imparts a constant downward force on the first andsecond bearings510,512 as indicated byarrow552 while acting against the retainingclip530. This constant downward force indicated byarrow552 eliminates potential for outer housing rotation when theshaft504 andblade assembly501 are rotating in use. As further shown inFIG. 12, the threaded retainingnut528 includes alower brake surface529 for use with a brake mechanism as further described below.
Referring now toFIG. 14, the blendingappliance10A is shown with theblender jar24A having a cover orlid560 disposed on and received in anopen top561 of theblender jar24A. Theopen top561 of theblender jar24A opens into thereceptacle portion24C of theblender jar24A. Thelid560 is a flexibly resilient and removable lid having alower ring portion562 with aseal member564 disposed around a periphery thereof. In assembly, thelower ring portion562 is received within areceptacle portion24C of theblender jar24A. Thelid560 further includes anupper portion566 with acentral aperture570. Thecentral aperture570 is disposed beneath thecup assembly407 of thefeed chute assembly400 disposed within theupper housing402. In this way, thefeed chute assembly400 is in communication with thereceptacle portion24C of theblender jar24A along a food path as indicated byarrow580. Further, thefeed chute assembly400 may be received inaperture570 to close offaperture570 when the blender jar2A andlid560 are removed from the blendingappliance10A, and to act as a feed chute directly into blender jar2A. Thelid560 includes anouter edge portion568 which abuts and seals against theopen top561 of theblender jar24A. Theouter edge portion568 tapers upwardly via a ramped or raisedportion569 culminating at thecentral aperture570 to define theupper portion566 of thelid560. The raisedportion569 contacts theupper housing402 to form a seal there between. Theupper housing402 generally exerts a downward force on thelid560 as indicated byarrow582. This downward force orpressure582 is realized on thelid560 as theblender jar24A is laterally inserted into a jar receiving portion orarea16A. Alower portion403 of theupper housing402 remains static as theblender jar24A is received in thejar receiving area16A, and thelid560 is resiliently flexible, such that the raisedportions569 abut the generally planarlower portion403 of theupper housing402 to form a seal between theblender jar24A and theupper housing402 ataperture570. In this way, positional tolerances are taken up as thelid560 is always held down to theblender jar24A during use by the engagement of thelid560 with theupper housing402. The constant downward force indicated byarrows582 reduces the chances of thelid560 becoming displaced from theopen top561 of theblender jar24A due to food contents surging during the startup of a blending procedure, or other upward forces acting on thelid560. Thus, thelid560 is retained on theblender jar24A when theblender jar24A is received in thejar receiving area16A of thehousing12A.
Referring now toFIG. 15, aninterlock switch assembly600 is shown. Theinterlock switch assembly600 includes aswitch housing602 which is disposed within an interior402A of theupper housing402 of blendingappliance10A. Theswitch housing602 includes a generallyvertical portion602A and a generallyhorizontal portion602B. Disposed on thevertical portion602A, one or more electrical airgap switch assemblies604 are mounted, as shown in this embodiment, to mountingposts606 and upper andlower clip mechanisms608 and610. In this way, one or moreelectrical switch assemblies604 are snap-fit to theswitch housing602. Thehorizontal portion602B of theswitch housing602 is secured to thelower portion403 of theupper housing402 via mountingcylinders612,614. The mountingcylinders612,614 are disposed on mountingposts403A,403B of thelower portion403 of theupper housing402. Thehorizontal portion602B of theswitch housing602 is coupled to the mountingposts403A and403B using fasteners. A spring-biasedrocker lever620 is pivotally coupled to thehorizontal portion602B of theswitch housing602 aboveaperture403C disposed in the lower portion03 ofupper housing402. Thelever620 includes first, second, and third contact surfaces622,623, and624, which are disposed along a periphery of amain body portion626. Thelever620 is a spring-biased rocker lever which is operable between ON and OFF positions as further described below.
Referring now toFIGS. 16A and 16B, theinterlock switch assembly600 is shown with theswitch housing602 having theswitch assembly604, shown inFIG. 15, removed. Thebody portion626 of thelever620 includes an outwardly extending mountingrod628 and aretention clip630. Atorsion spring632 is mounted on the mountingrod628 and includes an outwardly extendingarm634 which is retained by theretention clip630 to bias thelever620 to an “OFF” position as shown inFIG. 16A. As further shown inFIG. 16A, the mountingrod628 is nested into apivot cradle636 disposed on thehorizontal portion602B of theswitch housing602. Thetorsion spring632 biases thelever620 to the OFF position in a direction as indicated byarrow638. As shown inFIG. 16A, when theswitch620 is in the OFF position, thefirst contact surface622 is disposed below thehorizontal portion602B of theswitch housing602 and extends throughaperture403C into the blenderjar receiving area16A. Thesecond contact surface623 abuts anabutment portion603 disposed on thehorizontal portion602B to limit the movement of alever620 in the direction indicated byarrow638.
Referring now toFIG. 16B, thelever620 is shown in an “ON” position such that thelever620 is adapted to articulate between ON and OFF positions along an arcuate path as indicated by arrow R2. In the ON position, thetorsion spring632 is loaded and prepared to move thelever620 to the OFF position as shown inFIG. 16A by a biasing force. When in the ON position, thethird contact surface624 of thelever620 abuts anabutment portion605 of theswitch housing602.
Referring again toFIG. 15, thelever620 is moved to the ON position when theblender jar24A is received in ajar receiving area16A of the blendingappliance10A as further described above with reference toFIG. 14. Thelid560 of theblender jar24A has anupper-most portion569A disposed on the raised or rampedportion569 of thelid560. As theblender jar24A is received in thejar receiving area16A, theupper-most portion569A of thelid560 contacts thefirst contact surface622 of thelever620 which protrudes fromaperture403C of thelower portion403 of theupper housing402 into thejar receiving area16A. This engagement between therocker lever620 and thelid560 causes thelever620 to move or rotate to the ON position as shown inFIGS. 15 and 16B. In the ON position, thelever620 activates theair gap switch604 to provide power to the blendingappliance10A as further described below. When theblender jar24A is removed from the blendingappliance10A, thetorsion spring632 biases thelever620 to the OFF position, such that the blendingappliance10A is cut-off from power by theinterlock switch assembly600. As further shown inFIG. 15, thethird engagement surface624 is adapted to contact aswitch mechanism607 disposed on theswitch assembly604 which in turn activates anactivation button609 to provide power to the blendingappliance10A when thelever620 is in the ON position. In this way, theinterlock switch assembly600 is configured to selectively provide power to the blendingappliance10A by engagement with theblender jar24A. It is further contemplated that in another embodiment theblender jar24A can engage therocker lever620 without thelid560 in place on theblender jar24A.
Referring now toFIG. 17, theblender jar24A is received in the blenderjar receiving area16A in a generally horizontal or lateral direction as indicated by arrow H. The blendingappliance10A, as shown inFIG. 17, also includes amotor compartment14A which houses amotor20A. Themotor20A is adapted to drive amotor drive shaft92A having upper andlower portions92B and92C. In assembly, thelower portion92C is adapted to drive theblade assembly501 disposed within thereceptacle portion24C of theblender jar24A through abelt drive system678 as further described below. Theupper portion92B is coupled to aducted fan650 which operates in a similar manner to fan106 described above with reference toFIG. 3. Thefan650 is adapted to draw air through a ventedportion14B of themotor compartment14A, and then exhaust air through a ventedportion22B disposed on the support pad orbase22A along a venting path as indicated by arrow G. In this way, the ventedportion14B of themotor compartment14A defines an air intake portion of themotor compartment14A to draw air into themotor compartment14A from an exterior environment of the blendingappliance10A. As indicated by arrow G, the air drawn from the intake or ventedportion14B of themotor compartment14A is pulled towards theducted fan650 where it is then directed towards heat producingboard components20B of themotor20A. Thecomponents20B of themotor20A generate heat during use of the blendingappliance10A. As the air is pushed through themotor compartment14A, the air is exhausted out of the ventedportion22B of the support pad orbase22A as shown along the venting path indicated by arrow G. In this way, theducted fan650 is adapted to prevent or minimize the likelihood of themotor20A overheating during the operation of a blending function of the blendingappliance10A. It is further contemplated that thefan650 can be mounted to thelower portion92C ofmotor drive shaft92A to draw air through themotor compartment14A.
Referring again toFIG. 17, the blendingappliance10A includes, in the illustrated embodiment, aspeaker660 which is disposed on theupper housing402 adjacent the user-interface440. Thespeaker660 may be directly connected to themain PCB490 of the user-interface440 and may be coupled to acontroller664 through a lead662 shown inFIG. 17. In the embodiment shown inFIG. 17, thecontroller664 is housed within themotor compartment14A, however, thecontroller664 may be housed anywhere within the blendingappliance10A, such as theupper housing402. Thecontroller664 is configured to store and run automated blending sequences or functions F (FIG. 11A) by controlling the speed of themotor20A. Thus, the function settings F correlate to preprogrammed blending sequences stored in thecontroller664. Thespeaker660 is adapted to provide an audible tone which may signal the completion of a specific function, such as any one of the functions F as described above with reference toFIGS. 11A-11B. In use, it is contemplated that the user-interface440 would be used to select a function F that would be relayed through the user-interface lead662 to thecontroller664 which will then electronically relay a signal tospeaker660 to audibly indicate the status of a function F of the blendingappliance10A. The status may indicate the completion of a function F, or may further indicate that a setting is incorrect, such as theblender jar24A not being fully received in thejar receiving area16A. Thus, thecontroller664 includes a number of audio files that can be played through thespeaker660.
As further shown inFIG. 17, thecontroller664 may also be coupled to aUSB port668 such that the blendingappliance10A may be coupled to another electronic device, such as a portable electronic device, for loading different blending functions, programs or other protocols into thecontroller664. Awireless receiver670 is also shown inFIG. 17 which may be used to wirelessly couple thecontroller664 of the blendingappliance10A to a data-transfer protocol of a portable electronic device to load recipes, various audible tones, instruction information, use and care guides, and other such remote files that can be stored in thecontroller664 and audibly played through thespeaker660. Thewireless receiver670 can also be used to wirelessly upload preprogrammed blending sequences to thecontroller664.
Referring now toFIG. 18, another embodiment of ablender apparatus10B is shown having a number of features which are similar to the blendingappliance10 and10A described above. Thus, similar reference numerals will be used for like components using the suffix “B.” Referring now toFIGS. 18-19, blendingappliance10B generally includes ahousing12B having amotor compartment14B and ajar receiving area16B. Amotor20B is disposed in themotor compartment14B and a support pad orbase22B is operably coupled to thehousing12B. Ablender jar24B includes alid26B having afeed chute30B. Theblender jar24B andlid26B are configured to be received in thejar receiving area16B in a lateral direction as indicated by arrow H. As noted above, most traditional blending appliances include a construction that mandates vertical or drop-in placement of a jar onto a base that includes a motor therein. These types of constructions generally require substantial vertical space above the base to couple the jar to the base and for mechanically connecting the blades of the jar with a drive mechanism. The driving of the blending mechanism of the embodiment shown inFIGS. 18-19, does not require such a mechanical coupling as further described below.
With specific reference toFIG. 18, the blendingappliance10B includes amotor drive shaft92B which is rotatably driven by themotor20B and further includes anupper end93B and alower end95B. Theupper end93B is coupled to and adapted to drive anexhaust fan106B to ventilate themotor compartment14B. Thelower end95B ofmotor drive shaft92B is adapted to power or drive afirst pulley680A which is connected to asecond pulley680B via abelt682 in thebelt drive system678. Thesecond pulley680B is coupled to ashaft684 which is adapted to rotate along a rotational path R3as powered by themotor20B through thebelt drive system678. Amagnetic coupling system700 includes upper and lowermagnetic couplers702 and704. The lowermagnetic coupler704 is coupled toshaft684 and is disposed within thesupport base22B of the blendingappliance10B. The lowermagnetic coupler704 is rotatably disposed adjacent to a receivingdeck706 of thejar receiving area16B which encapsulates the lowermagnetic coupler704 within thesupport base22B. Thesecond pulley680B may be an integrated part of the lowermagnetic coupler704, or may be a separate part disposed on a shared drive shaft, such asshaft684. The uppermagnetic coupler702 is rotatably disposed within abase portion62B of theblender jar24B. The uppermagnetic coupler702, as disposed within thebase portion62B of theblender jar24B, is removable from the blendingappliance10B when theblender jar24B is removed from thejar receiving area16B. The uppermagnetic coupler702 is coupled to ashaft708 which is further coupled to adrive shaft710 at alower end712. Anupper end714 of thedrive shaft710 is connected to ablade assembly716 which is fully disposed within areceptacle portion24C of theblender jar24B. Driveshaft710 andshaft708 are shown inFIG. 18 as separate parts, but may be combined to form a unitary drive shaft for rotating the uppermagnetic coupler702 andblade assembly716. As further shown inFIG. 18, themagnetic coupling system700 magnetically couples theblender jar24B to thebase portion22B of the blendingappliance10B through the magnetic attraction generated between upper and lowermagnetic couplers702,704, as further described below. As shown in the embodiment ofFIG. 18, the upper and lowermagnetic couplers702,704, have a generally circular or disc configuration at a prescribed diameter, such that theblender jar24B will properly seat on the receivingdeck706 due to the magnetic coupling and attraction forces between the upper and lowermagnetic couplers702,704. In assembly, themotor20B drives thebelt682 of thebelt drive system678, as described above, thereby driving theshaft684 in a direction as indicated by arrow R3. This driving action powered by themotor20B drives the lowermagnetic coupler704 along the rotational path indicated by arrow R3as coupled to theshaft684. Due to the magnetic coupling of the lowermagnetic coupler704 to the uppermagnetic coupler702, the uppermagnetic coupler702 rotates along with the rotation of the uppermagnetic coupler704. As the uppermagnetic coupler702 rotates, thedrive shaft710, coupled thereto, also rotates in a direction as indicated by arrow R4which corresponds to the rotational path R3of the lowermagnetic coupler704. In this way, the upper and lowermagnetic couplers702,704 drive theblade assembly716 disposed within thereceptacle portion24C of theblender jar24B through a magnetic torque coupling, rather than a conventional mechanical coupling. Themagnetic coupling system700 is contemplated for use with all versions of the blending appliance herein.
In another embodiment, referring toFIG. 18, themagnetic coupling system700 magnetically couples theblender jar24B to thebase portion22B of the blendingappliance10B through inductance and magnetic reluctance generated between upper andlower couplers702 and704. In assembly, themotor20B drives thebelt682 of thebelt drive system678, as described above, thereby driving theshaft684 in a direction as indicated by arrow R3. This driving action powered by themotor20B drives the lowermagnetic coupler704 along the rotational path indicated by arrow R3as coupled to theshaft684. The rotating lower coupler made from an array of permanent magnets generates a rotation magnetic field. The upper coupler made from electrically conductive copper or copper alloy will react with this field through inductance. The electrical current generated in theupper coupler702 produces a magnetic field that is opposite from the field produced by thelower coupler704. Due to magnetic induction the upper coupler will rotate in the same direction as thelower coupler704 as indicated by arrow R3. As the uppermagnetic coupler702 rotates, thedrive shaft710, coupled thereto, also rotates in a direction as indicated by arrow R4which corresponds to the rotational path R3of the lowermagnetic coupler704. In this way, the upper and lowermagnetic couplers702,704 drive theblade assembly716 disposed within thereceptacle portion24C of theblender jar24B through a magnetic torque coupling, rather than a conventional mechanical coupling. Themagnetic coupling system700 is contemplated for use with all versions of the blending appliance herein.
Referring specifically toFIG. 19, themotor20B, as shown, is coupled to thebelt drive system678 atfirst pulley680A which is further connected tosecond pulley680B viabelt682 as described above. In the embodiment shown inFIG. 19, the blendingappliance10B includes aslide lock60B which operates in a manner similar to slidelock60 as described above with reference toFIG. 2. In the configuration shown inFIG. 19, the upper and lowermagnetic couplers702,704 are in the form of coupler discs having stepped portions. Thecoupler discs702,704 may be comprised of a magnetic material or may be in the form of a polymeric housing which includes a plurality of magnetic elements or a solid magnetic rings disposed along interfacingsurfaces720,722 of the upper and lowermagnetic couplers702,704 respectively.
Referring now toFIGS. 20A and 20B, thebase portion62B ofblender jar24B is shown having uppermagnetic coupler702A rotatably disposed therein. The uppermagnetic coupler702A includes a generallyplanar body portion730 in the form of a disc having a plurality ofmagnetic elements732 disposed along aperiphery734 of thedisc730. Themagnetic elements732 are disposed about theperiphery734 to define amagnetic array735. As shown, themagnetic elements732 are individual magnetic elements which are separated by portions of thedisc730 which is contemplated to be made of a non-magnetic polymeric material. In the embodiment shown inFIG. 20B, the uppermagnetic coupler702B includes adisc736 having a plurality ofmagnets738 disposed within anouter channel740 of thedisc736. In this configuration, the individualmagnetic elements738 are aligned on ametallic disc736 in thechannel740, such that themagnetic elements738 are not individually separated by a polymeric material, such as found in the embodiment ofFIG. 20A. While the configurations shown inFIGS. 20A and 20B include a plurality of individual magnetic elements, it is contemplated that themagnetic elements732,738, as disposed in the upper andlower coupling mechanisms702,704, may be comprised of continuous metallic rings, or other like shapes, defining upper and lower magnetic arrays to sufficiently magnetically couple the upper and lowermagnetic couplers702,704 in themagnetic coupling system700. Further, it is contemplated that themagnetic elements732,738 are permanent magnetic elements. Thepermanent magnets732,738 are “permanent” in that they create their own magnetic field which persists against influences which might otherwise demagnetize them.
Referring now toFIG. 21, abase22B andmotor20B are shown with thebelt drive system678 coupled to themotor20B and further coupled to another embodiment of a lowermagnetic coupler704A. In this embodiment, atensioner pulley679 is incorporated into thebelt drive system678 to reduce slack within thebelt682. As further shown in this embodiment, the lowermagnetic coupler704A includes adisc portion750 having a plurality ofmagnetic elements752 disposed within anouter channel754 of thedisc750. The magnetic array ofmagnetic elements752 shown in this embodiment is akin to the magnetic array ofmagnetic elements738 shown inFIG. 20B. Again, as noted above, themotor20B is adapted to drive the lowermagnetic coupler704A in a direction as indicated by arrow R3.
With regards to themagnetic coupling system700, as shown and described above, it is contemplated that a plurality of nonmagnetic layers will exist between the upper andlower coupling mechanisms702,704. Such nonmagnetic layers may be disposed on thesupport base22B of the blendingappliance10B, or may be included on thebase portion62B of theblender jar24B, or both. In this way, the magnetic elements disposed within the upper and lowermagnetic couplers702,704 do not directly contact one another, such that the torque provided by the lowermagnetic coupler704 will transfer to the uppermagnetic coupler702 purely through magnetic attraction forces that exist across the nonmagnetic layers as further described below.
Referring now toFIG. 22A,blender jar24B is shown having ablade assembly716 disposed within areceptacle portion24C of theblender jar24B. In this embodiment, theblade assembly716 is coupled to abearing assembly500 through adrive shaft710 which is further coupled, at alower portion712 thereof, to another embodiment of an uppermagnetic coupler702C. As further shown in this embodiment, the uppermagnetic coupler702C is part ofmagnetic coupling system700C, and generally includes, a disc orcarrier736C having achannel740C disposed around a periphery thereof. Thecarrier736C is comprised of a nonmagnetic material, such as a polymeric substance suitable for use with theblender jar24B. As further shown inFIG. 22A, abacking plate780 is disposed within thechannel740C and is coupled to amagnetic element738C, wherein themagnetic element738C defines an upper magnetic array. Thebacking plate780 may include any magnetic soft material or magnetizable material, such as a mild steel backing plate, suitable to provide for efficiencies in themagnetic coupling system700C as further described below. Thebacking plate780 may be a continuous backing plate disposed throughout thechannel740C of thecarrier736C. Further, it is contemplated that themagnetic element738C may be made up of discrete magnetic elements or a continuous magnetic ring disposed within thechannel740C. As further shown inFIG. 22, the uppermagnetic coupler702C is rotatably disposed within abase portion62C of theblender jar24B. Thebase portion62C includes alower bottom wall782 that closes off thebase portion62C to form a sealedcavity784 in which the uppermagnetic coupler702C is disposed. Anair gap786 is disposed between the uppermagnetic coupler702C and thebottom wall782 of thebase portion62C, such that thebottom wall782 and theair gap786 provide exemplary embodiments of the plurality of nonmagnetic layers disposed between the uppermagnetic coupler assembly702C and a lowermagnetic coupler704C (FIG. 23), as further described below.
Referring now toFIGS. 22B and 22C, thebase portion62C ofblender jar24B is configured to house the uppermagnetic coupler702C within the sealedcavity784 for rotation therein. As the uppermagnetic coupler702C rotates within the sealedcavity784, heat is generated, such that pressure can build-up within the sealedcavity784. Thus, as shown inFIG. 22B, aventing system787 is disposed on the sidewall of thebase portion62C which generally includes anaperture788, shown inFIG. 22C, formed through the sidewall of thebase portion62C having a one-way valve789 disposed therein. In assembly, theventing system787 is configured to allow for air to pass from the sealedcavity784 to the outside environment through thevalve789. In this way, as heat is generated by the movement of the uppermagnetic coupler702C within the sealedcavity784 to build-up pressure therein, that pressure can be relieved through theventing system787 which is shown inFIGS. 22B and 22C as a one-way check valve789. It is further contemplated that thevalve789 can be a membrane which coversaperture788, so long as the membrane allows for pressure equalization from the sealedcavity784 in use.
Referring now toFIG. 23, themagnetic coupling system700C is shown having the lowermagnetic coupler704C disposed within aninterior portion790 of thesupport base22C. In this embodiment, the lowermagnetic coupling portion704C is coupled to abelt drive system678C at abelt receiving portion792. Thebelt receiving portion792 further defines ahousing794 in which abearing assembly500C is disposed, much like bearing assembly500 disposed between theblade assembly716 and the uppermagnetic coupler702C as described above with reference toFIGS. 12 and 13. The bearingassembly500C is coupled toshaft684C, such that lowermagnetic coupler704C is adapted to rotate as driven by thebelt drive678C using belt682C. Much like uppermagnetic coupler702C, the lowermagnetic coupler704C includes acarrier disc portion750C having achannel754C disposed around a periphery thereof. Thecarrier disc750C is comprised of a nonmagnetic material similar tocarrier736C noted above. As further shown inFIG. 22A, abacking plate796 is disposed within thechannel754C and is coupled to amagnetic element752C. Again, thebacking plate796 is exemplary in nature, and may include any magnetic soft material or magnetizable material, such as mild steel. Thebacking plate796 may be a continuous backing plate disposed throughout thechannel754C of thecarrier disc750C. Further, it is contemplated that themagnetic element752C may be made up of separate and discrete magnetic elements or may be in the form of a continuous magnetic ring disposed within thechannel754C. Thus, the upper and lowermagnetic couplers702C,704C of themagnetic coupling system700C each include abacking plate780,796, respectively, which act as a short between north and south poles of adjacent magnet assemblies,738C,752C, thereby reducing inefficiencies in torque delivery as further described below with reference toFIG. 24.
Referring now toFIG. 24, a schematic drawing of themagnetic couplers702C and704C is shown with anupper backing plate780 and alower backing plate796. Four magnets M1, M2, M3, and M4 are positioned on the upper andlower backing plates780,796 as shown. Thus, magnets M1 and M4 are akin to themagnet elements752C shown inFIG. 23 for the lowermagnetic coupler704C, while magnets M2, M3 are akin tomagnetic elements738C shown inFIG. 23 for the uppermagnetic coupler702C. In this arrangement, an air gap AG is defined between the uppermagnetic coupler702C and the lowermagnetic coupler704C, which is akin toair gap782 shown inFIG. 23. The magnets M1 through M4 have alternating north and south poles (N, S) to define a magnetic field loop. When arranged in an arcuate orientation, the magnets M1 through M4, as disposed in the upper and lowermagnetic couplers702C,704C, create a magnet torque coupler across the air gap AG. The air gap AG provides for a frictionless interface between the upper and lowermagnetic couplers702C and704C, however, this air gap AG also produces undesired reluctance as further described below. With the air gap AG in place between the upper and lowermagnetic couplers702C,704C, a misalignment of the magnets M2, M3 with magnets M1, M4 will generate a torque that is easily corrected given the frictionless interface at the air gap AG.
As noted above, the air gap AG provides for reluctance in themagnetic coupling system700C. This reluctance is similar to resistance in an electric circuit. A magnetic field causes magnetic flux to follow the path of least magnetic reluctance in use. The larger the air gap AG, the higher the reluctance which would interfere with and ultimately reduce the magnetic attraction, indicated by arrows MA, and result in lower magnetic torque capacity for the blending appliance between the upper and lowermagnetic couplers702C,704C. Having the upper and lowermetallic backing plates780,796, which are made of a metallic material or soft magnetic material such as mild steel or any other magnetizable material, reduces the reluctance between the north and south poles on the backside of the magnets M1-M4. In this way, theback plates780,796 act as a short between north and south poles of adjacent magnets, thereby increasing the magnetic attraction MA disposed across the air gap AG. Any reluctance from the air gap AG is a loss of efficiency, such that thebacking plates780,796 increase the efficiency, or magnetic attraction MA, and torque capacity of themagnetic coupling system700C by reducing the reluctance caused by the air gap AG. Thus, thebacking plates780,796 increase the efficiency of themagnetic coupling system700C by minimizing any stray magnetic field that may exist in the system, such that magnetic attraction between the magnets M1-M4, is focused or otherwise maximized.
Referring now toFIG. 25A, abrake system800 is shown for use in conjunction with another embodiment of the uppermagnetic coupler702D. In this embodiment, ablade assembly716 is coupled to ashaft710 having alower portion712. Thelower portion712 includes steppedcoupling portions802 and804. In this embodiment, uppermagnetic coupler702D includes acentral hub806 which has a brake surface orbrake ring808 disposed around thecentral hub806. Thebrake surface808 is disposed on anupper portion810 of the uppermagnetic coupler702D. Thecentral hub806 defines aninterior cavity812, in which abiasing mechanism814 is disposed around aninner column816 of thecentral hub806. Thebiasing mechanism814 is shown in the form of a coil spring, and is retained within thecavity portion812 of thecentral hub806 by aretainer plug820 which includes a pressfit portion822 and aslideable interface portion824. In use, the retainingplug820 is adapted to provide an outer slidinginterface826 between theslideable interface portion824 of theretainer plug820 and theinner column816 of thecentral hub806. Thebrake system800 further comprises anupper brake surface830 which is disposed on, or adjacent to, thebearing system500 of theblender jar24B. InFIG. 25A, thebrake surface808 is considered a lower brake surface which is spaced apart from theupper brake surface830. Thus, in the disengaged position ofFIG. 25A, it is contemplated that the uppermagnetic coupler702D is being pulled downward by a magnetic attraction, indicated by arrow MA, towards a lower magnetic coupling mechanism. Thus, the magnetic attraction MA provides for a force strong enough to overcome the biasing force of thebiasing mechanism814 to allow the uppermagnetic coupler702D to be moved downward such that the upper and lower brake surfaces830,808 are not engaged. In this way, the upper magnetic coupled702D can freely rotate and drive theblade assembly716 in the disengaged position.
Referring now toFIG. 25B, thebrake system800 is shown in an engaged position, wherein theupper brake surface830 is in contact with thelower brake surface808. Thus, thebrake mechanism800 is in an engaged position, wherein the uppermagnetic coupler702D is in a braking position, such that the uppermagnetic coupler702D is no longer free to rotate. As shown inFIG. 25A, theblender jar24B is disposed on the receivingdeck706, such that theblender jar24B is likely coupled to a lower magnetic coupling mechanism that is providing the magnetic attraction MA necessary to overcome the biasing force of thebiasing mechanism814 and lower the upper magnetic coupled702D to the free rotation position. As shown inFIG. 25B, theblender jar24B has been removed from the receivingdeck706, such that the uppermagnetic coupler702D no longer has the magnetic attraction force pulling the uppermagnetic coupler702D downward towards the disengaged position shown inFIG. 25A. Thus, the uppermagnetic coupler702D is adapted to move vertically in a direction as indicated byarrow832 between the engaged and disengaged positions. This movement in a vertical direction, as indicated byarrow832, occurs at theslideable interface826inner column816 of thecentral hub806 and theretainer plug820. The engagement ofupper brake surface830 withlower brake surface808 stops the rotation of the uppermagnetic coupler702D via friction between the twobrake surfaces830,808. Thus, when a user removes theblender jar24B from the blender base, uppermagnetic coupler702D will move upward to the engaged position, and theblade assembly716 will stop its rotation due to the interaction of the brake surfaces830,808 of thebrake system800 as discussed above. Theblade assembly716 can ramp up a significant amount of inertia in use, such that the, without thebraking system800, a user could be exposed to moving blades with in the jar.
Referring now toFIG. 26, another embodiment of abrake system800A is shown as used with another embodiment of amagnetic coupler assembly700E. Thebrake system800A incorporates bearingassembly500, which is similar to bearingassembly500 described and shown above with reference toFIG. 12. Thus, as shown inFIG. 26, the threaded retainingnut528 is threadingly coupled to theretainer member520, which thereby couples the bearingassembly500 to receivingaperture550 disposed on theblender jar24A. As noted with reference toFIG. 12, the threaded retainingnut528 includes abrake surface529 which is shown inFIG. 26 as being disposed above and adjacent to alower brake surface850 disposed on yet another embodiment of the uppermagnetic coupler702E. Thelower brake surface850 is disposed on aring bracket852 which is biased by abiasing mechanism854, shown inFIG. 26 in the form of a coil spring, that is disposed around acentral hub856. The biasingspring854 biases thering bracket852 upward, such that thelower brake surface850 will rise up to contact theupper brake surface529 to effectively stop the rotation of the uppermagnetic coupler702E via friction betweensurfaces529,850. Thebrake system800A further includesmagnetic element860 which is disposed along alower surface862 of the uppermagnetic coupler702E. Thismagnetic element860 can be in the form of a ring or otherwise comprised of discrete magnetic elements. The lowermagnetic coupler704E similarly includesmagnetic element870 disposed in a generally central location along theupper surface872 of lowermagnetic coupler704E directly belowmagnetic element860. In assembly, themagnetic elements860,870 are magnetically attracted to one another with enough magnetic force to overcome the biasing force produced by the biasingspring854. In this way, the magnetic attraction betweenmagnetic elements860,870 moves the lower brake surfaces850 away from theupper brake surface529 disposed on the threaded retainingnut528 of thebearing system500. Thus, thebrake system800A, shown inFIG. 26, provides for amoveable brake surface850 disposed within the uppermagnetic coupler702E, such that the brake surfaces andring bracket850,852 are the only portions of the uppermagnetic coupler702E that are adapted to move. In this way, thebody portion736E of the uppermagnetic coupler702E remains vertically stationary, such that the uppermagnetic coupler702E is less prone to wobble or vibration during rotation. As further shown inFIG. 26,magnetic elements864 are disposed at an outer periphery of the uppermagnetic coupler702E and are adapted to magnetically coupling withmagnetic elements866 disposed in the lowermagnetic coupler704E.
Referring now toFIGS. 27A and 27B, another embodiment of ablender jar900 is shown. Theblender jar900 includes areceptacle portion902 and alower coupling portion904. Theblender jar900, like the jar assemblies noted above, is adapted to be received in a housing module by laterally movement of thejar900 into a jar receiving area of the housing. As shown inFIGS. 27A and 27B, theblender jar900 includes a removable twist-onbase collar906 which couples to thelower coupling portion904 of theblender jar900. Thelower coupling portion904 includes engagement features905 which are adapted to engage reciprocal features disposed in achannel908 of thebase collar906 in a locking configuration. In this way, thelower coupling portion904 seals against thechannel908 of thebase collar906, as shown inFIG. 27B. As shown inFIG. 27A, an upwardly extendingblade assembly910 is centrally disposed on thebase collar906, and is adapted to be received in thereceptacle portion902 of thejar900 through alower aperture912 disposed on thejar900. Theblade assembly910 is mounted on ashell914 which houses a heating element, as further described below. Alower portion916 ofbase collar906 includes afemale power socket920, which is adapted to receive a male connection pin, or other like power connector, as thejar900 is laterally received in a blender housing. It is contemplated that theshell914 and thejar900 are composed of a highly thermally conductive material such as metal (stainless steel) or glass for use with the heating element as further described below.
Referring now toFIG. 27C, theblender jar900 is shown with theblade assembly910 disposed within the interior cavity orreceptacle portion902. Adrive shaft922 is coupled to abearing assembly924 and is adapted to rotatably drive theblade assembly910 within thereceptacle portion902 of theblender jar900 during a blending function. As further shown inFIG. 27C, a heater orheating element926 is coupled to thebase collar906 and disposed about the bearingassembly924.
As best shown inFIGS. 27D and 27E, theheating element926 generally includes acalrod heater coil928 disposed within theshell914, wherein thecoil928 is surrounded by aheat transferring material930. Thecoil928 is shown in the form of a calrod wire or coil which is adapted to produce heat via an electric current. Other such heating elements can also be used with this embodiment. Theheating element926 further includes ahousing932, wherein the bearingassembly924 is disposed in assembly. Theheating element926 further includes acavity portion934 having alower flange portion936 disposed thereabout. Thelower flange portion936 includes a plurality of mountingapertures937 disposed therealong for mounting theheating element926 to thebase collar906. Disposed within thecavity934, male connection pins938 are disposed for coupling tofemale connection ports940 disposed within thecollar906. Thefemale connection ports940 are further coupled to a lead942 that is in communication with thepower port920 for powering thecalrod coil928 of theheating element926. As noted above, it is contemplated that theouter shell914 of theheating element926 is comprised of a metallic material, such that heat produced by thecalrod heater coil928 is conductively transferred to theblender jar900 in use, as thebase collar906 andreceptacle portion902 are in thermal communication with one another. Thus, in use, theheating element926 allows the user to heat the contents of theinterior cavity902 of theblender jar900, while also performing a blending function, such as for use when preparing soups and other warm purees. Further, it is contemplated that theheating element926 may be comprised of a die-cast aluminum member having a non-stick coating, thereby obviating the need for anouter shell914.
Referring now toFIG. 28A, another embodiment of aheating element926A is shown wherein acalrod heater coil928 is disposed within themetallic shell914, such thatheating element926A is suitable to heat the thermallyconductive blender jar900 in use, much likeheating element926 described above. Theheating element926A further includes a portion of thecalrod heater coil928 disposed within thereceptacle portion902 of theblender jar900. As further shown in the embodiment ofFIG. 28A, theheating element926 includes apower lead942 that is disposed within thebase collar906, and which further culminates in amale connector pin944 which extends outwardly from thebase collar906. Themale connector pin944 is adapted to electrically couple with a female connection header orport946. In assembly, it is contemplated that thefemale connection header946 is disposed along the blender housing for coupling with themale connector pin944 to power theheating element926A.
Referring now toFIG. 28B, another embodiment of aheating element926B is shown in the form of acalrod heating element928 disposed within another embodiment of the twist-onbase collar906B. In this embodiment, thebase collar906B includes ametallic ring portion948 which is disposed adjacent thecalrod heating element928. In this way, themetallic ring portion948 of thebase collar906B is in thermal communication with themetallic shell914 of theheating element system926B. Thus, heat produced by thecalrod heating element928 can radiate through themetallic shell914 from thebase collar906B, into the thermallyconductive blender jar900. Likeheating element926A described above,heating element926B also includes a portion of thecalrod heater coil928 disposed within thereceptacle portion902 of theblender jar900 for directly heating the contents of theblender jar900.
Referring now toFIG. 29A, an exploded view of a thickfilm heater plate950 is shown having acover coat952, a film circuit954, a first bioelectric coating956, acensor layer958, a second bioelectric coating960 and a carriersheet metal plate962. As shown inFIG. 29B, the component parts noted above are assembled to form a unitary thickfilm heater plate950. The thickfilm heater plate950 provides for another embodiment of aheating element926C as shown inFIG. 29C. As specifically shown inFIG. 29C, the thickfilm heater plate950 is disposed below and adjacent to the metallic outer casing or shell914 ofheating element926C. Thus, heat produced by the thickfilm heater plate950 is conductively transferred to theblender jar900 through the casing orshell914, which, as noted above, is highly thermally conductive.
Referring now toFIG. 29D, the thickfilm heater plate950 is disposed within a cavity portion of the base collar906D, to create another embodiment of aheating element926D. The base collar906D includes ametallic ring948D which is in thermal communication with themetallic shell914 of theheating element system926D. Thus, heat produced by the thickfilm heater plate950 can radiate through themetallic shell914 from the base collar906D, into the thermallyconductive blender jar900 for heating a food substrate disposed in thereceptacle902.
Referring now toFIG. 30, another embodiment of anupper housing assembly970 is shown for a blendingappliance10C. Theupper housing assembly970 includes anaperture972 having a lockingring974 disposed therein. Thelocking ring974 is adapted to couple a number of blender accessories as further described below. In assembly, it is contemplated that theaperture972 opens into afeed chute976 that is disposed through theupper housing970 and which further opens into the receptacle portion of a blender jar. Theupper housing970 further includes a forward facinguser interface module978 in the form a rotatable dial, much likedial442 described above. Theupper housing970 is considered a powered housing, as theupper housing970 includes apower module980 having metallizedconnection pads982 disposed thereon. Thepower module980 is contemplated to be coupled to a lead that connects with the power supply for the blendingappliance10C and theuser interface978. As an exemplary accessory, anice shaver attachment1000 is shown exploded away from theupper housing970. Theice shaver attachment1000 includes acoupling hub1002 having aconnectivity pad1004 disposed there on. Thecoupling hub1002 is adapted to couple to thelocking ring974 disposed in theaperture972, via engagement features1006 disposed on thecoupling hub1002. The engagement features1006 are twisted into place by turning theice shaving attachment1000 in a direction as indicated byarrow1016. As coupled in place, the engagement features1006 ensure that theconnectivity pad1004 of thecoupling hub1002 aligns with an electronically couples to theconnection pads982 of thepower module980 to provide power to a motor and blade assembly disposed within a housing1010 of theice shaving attachment1000. Disposed on either side of the housing1010 is anintake chute1012 for receiving ice and afeed chute1014 which is adapted to feed shaved ice to thefeed chute976 of theupper housing970. In this way, the blendingappliance10C is capable of powering an accessory, like the shavedice attachment1000 for easily blending frozen concoctions. Thepower module980 is contemplated to be able to power a host of accessories, such as a hot plate or a coffee machine, and non-powered accessories can also be attached to lockingring974, such as a strainer, a filter, etc.
Referring now toFIG. 31, another embodiment of the blendingappliance10D is shown which incorporates several of the features discussed above. Specifically, the blendingappliance10D includes afeed chute assembly400 disposed withinupper housing402. Disposed within an interior402A of theupper housing402, aninterlock switch assembly600 is coupled to alower portion403 of theupper housing402. On a front portion of theupper housing402, auser interface440 is shown in the form of arotating dial442. Ablender jar24D is laterally received in a jar receiving area16D in a substantially horizontal manner as indicated by arrow H. In the embodiment shown inFIG. 31, theblender jar24D is received within the jar receiving area16D on receivingdeck706. Theblender jar24D further includes alid560 which is in abutting engagement with thelower portion403 of theupper housing402. Theblender jar24D is shown in open communication with thefeed chute assembly400 through to areceptacle portion24C of theblender jar24D. Ablade assembly506 is further disposed within thereceptacle portion24C of theblender jar24D and is coupled to adrive shaft504 received within a bearingassembly500. Amagnetic coupling system700E includes an uppermagnetic coupler702E disposed within abase portion62D of theblender jar24D. A lowermagnetic coupler704E is disposed within thesupport base22 of the blendingappliance10D. The lowermagnetic coupler704E is operably coupled to abelt drive system678 which is further coupled to a motor20D disposed within amotor compartment14. In use, themotor20B is adapted to drive thebelt drive system678 to rotate the lowermagnetic coupler704E which in turn rotates the uppermagnetic coupler702E through magnetic forces to power theblade assembly506 within thereceptacle portion24C of theblender jar24D. Themagnetic coupling system700E further includes abrake mechanism800A which is disposed on the uppermagnetic coupler702E and adapted to engage a lower portion of the bearingassembly500 when theblender jar24D is laterally removed from theblender housing12 to stop rotation of the uppermagnetic coupler702E. Afan member650 is disposed on anupper portion92B of amotor drive shaft92A. Themotor drive shaft92A is coupled to and driven by themotor20B in assembly. It is further contemplated that thefan member650 may be disposed at alower end92C of themotor drive shaft92A for venting the heat produced by themotor20A andother board components20B of themotor20A. As coupled to thelower portion92C of themotor drive shaft92A, thefan member650 will draw air from the ventedportion14B of themotor compartment14, to then be exhausted out ventilatedportions22B of thesupport base22. In this way, a high pressure area in themotor compartment14, is separated from a low pressure area of thesupport base22.
It is contemplated that for any of the embodiments disclosed herein that the drive system could include a series of gears or belts, as generally described. With regard to all of these embodiments, it is contemplated that various components of certain embodiments may be utilized across different embodiments. For example, the auger assembly generally illustrated in the embodiments ofFIGS. 4 and 5 could also be utilized in the first embodiment shown inFIGS. 1-3 to minimizing food bridging. In addition, for each of the embodiments disclosed herein, the blendingappliance10 is designed for unassisted operational blending. More specifically, a user can insert a jar into a jar receiving area, and once the jar is received in the jar receiving area, the jar can be secured in place via the upper locking tab or the base jar lock. The user can then activate the blendingappliance10 and leave the area. Monitored blending of the blendingappliance10 is not required. In addition, because of the construction of the blending appliances disclosed herein, and the lateral insertion of the jar into the jar receiving area, a lowprofile blending appliance10 can be maintained that is aesthetically pleasing and does not require substantial vertical space above the blendingappliance10.
It is also important to note that the construction and arrangement of the elements of the concept as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.
It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present concept. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.
It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present concept, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.
