Serve one serving of chilled food and drink.

Abstract

To provide systems and methods that rapidly cool contents of pods containing an ingredient for food and drinks.SOLUTION: A system for producing single servings of cooled food or drinks from ingredients in a pod containing the ingredients includes: an evaporator 108 of a refrigeration system 109, the evaporator having an aluminum side wall defining a receptacle 110 sized to receive the pod; and a processor 122 configured to control the refrigeration system to cool the pod while the pod is positioned in the receptacle of the evaporator, to control a motor 124 operating a drive shaft 126 of the machine to agitate the ingredients to produce a single serving of cooled food or drink from the pod while the refrigeration system cools the pod, and to control opening of the pod to dispense a single serving of cooled food or drink from the pod.SELECTED DRAWING: Figure 1B

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This patent application is a continuation-in-part of U.S. Ser. No. 16 / 104,758, filed August 17, 2018, and claims the benefit of provisional patent applications U.S. Ser. No. 62 / 758,110, filed November 9, 2018, U.S. Ser. No. 62 / 801,587, filed February 5, 2019, U.S. Ser. No. 62 / 831,657, filed April 9, 2019, U.S. Ser. No. 62 / 831,600, filed April 9, 2019, U.S. Ser. No. 62 / 831,646, filed April 9, 2019, and U.S. Ser. No. 62 / 831,666, filed April 9, 2019, the disclosures of which are incorporated herein by reference in their entireties.

[0002] The present disclosure relates to a system and method for rapidly cooling food and drinks. [Background technology]

[0003] Beverage production systems have been developed to rapidly prepare single servings of hot beverages. Some of these systems utilize disposable pods to which water is added before production. The pods can be used to prepare hot coffee, tea, cocoa, and dairy-based beverages.

[0004] Home ice cream makers can be used to make larger servings of ice cream (e.g., 1.5 quarts or more) for personal consumption. These ice cream maker appliances typically prepare the mixture by means of a hand crank or an electric motor that in turn is used to assist in the stirring of the ingredients within the appliance. The resulting mixture is often chilled using a pre-cooled container inserted into the machine. Summary of the Invention [Means for solving the problem]

[0005] This specification describes systems and methods for rapidly cooling food and drinks. Some of these systems and methods can cool food and drinks from room temperature to frozen in less than two minutes inside a container inserted on a countertop or in a stationary machine. For example, the approach described herein has successfully demonstrated the ability to make soft serve ice cream from a room temperature pod in approximately 90 seconds. This approach has also been used to chill cocktails and other drinks, including creating frozen drinks. These systems and methods are based on a pod-machine interface that provides fewer activations of the refrigeration cycle and is easy to use and highly efficient heat transfer. Some of the pods described are filled with ingredients in the production line and undergo a sterilization process (e.g., retort sterilization, aseptic packaging, ultra-high temperature processing (UHT), ultra-heat processing, ultra-high temperature pasteurization, or high pressure processing (HPP)). HPP is a pasteurization method in which a product already sealed in its final package is introduced into a container and subjected to high levels of isostatic pressure (300-600 megapascals (MPa) (43,500-87,000 pounds per square inch (psi)) transmitted by water. The pods can be used, for example, to store ingredients, including dairy products, at room temperature for extended periods of time (e.g., 9-12 months) after pasteurization.

[0006] Cooling is used to refer to the transfer of thermal energy, for example, to reduce the temperature of ingredients contained in a pod. In some examples, cooling refers to the transfer of thermal energy, for example, to reduce the temperature of ingredients contained in a pod to below freezing.

[0007] Some machines for producing chilled food or drinks from ingredients in pods containing the ingredients include an evaporator in a refrigeration system defining a receptacle sized to accommodate the pod, the refrigeration system having a working fluid loop extending from the evaporator to a compressor, a condenser, an expansion valve or capillary tube, and back to the evaporator, and also including a first bypass line extending from the working fluid loop between the compressor and the condenser to the working fluid loop between the expansion valve and the evaporator.

[0008] Some machines for reducing the temperature of ingredients in a pod containing the ingredients and at least one mixing paddle include an evaporator in a refrigeration system defining a receptacle sized to receive the pod, and a motor operable to move at least one internal mixing paddle of the pod within the receptacle, the refrigeration system having a working fluid loop extending from the evaporator to a compressor, a condenser, an expansion valve, and back to the evaporator, a first bypass line extending from the working fluid loop between the compressor and the condenser to the working fluid loop between the expansion valve and the evaporator, and also including a bypass valve in the first bypass line.

[0009] Some machines for producing a cooling ingredient in a pod containing the ingredient and at least one internal mixing paddle include an evaporator of a refrigeration system defining a receptacle sized to receive a disposable pod, and a motor operable to move at least one internal mixing paddle of the pod within the receptacle, the refrigeration system having a working fluid loop extending from the evaporator to a compressor, a condenser, an expansion valve, and back to the evaporator, a first bypass line extending from the working fluid loop between the compressor and the condenser to the working fluid loop between the expansion valve and the evaporator, and also including a bypass valve in the first bypass line.

[0010] Some machines for producing a chilled ingredient in a pod containing the ingredient and at least one internal mixing paddle include an evaporator of a refrigeration system defining a receptacle sized to receive the pod, and a motor operable to move the internal mixing paddle of the pod within the receptacle, the refrigeration system having a working fluid loop extending from the evaporator to a compressor, a condenser, an expansion valve, and back to the evaporator, and also including a first bypass line extending from the working fluid loop between the compressor and the condenser to the working fluid loop between the evaporator and the compressor.

[0011] Some machines for producing a chilled ingredient in a pod containing the ingredient and at least one internal mixing paddle include an evaporator in a refrigeration system defining a receptacle sized to receive the pod, and a motor operable to move the pod's internal mixing paddle within the receptacle, the refrigeration system having a working fluid loop extending from the evaporator to a compressor, a condenser, a pressure vessel, an expansion valve, and back to the evaporator, the working fluid loop including a first shutoff valve between the pressure vessel and the expansion valve, and a second shutoff valve between the compressor and the condenser.

[0012] Some machines for producing a cooled ingredient in a pod containing the ingredient and at least one internal mixing paddle include an evaporator in a refrigeration system defining a receptacle sized to receive the pod, and a motor operable to move the pod's internal mixing paddle within the receptacle, the refrigeration system having a working fluid loop extending from the evaporator to a compressor, a condenser, an expansion valve, and back to the evaporator, the working fluid loop passing through a thermoelectric cooler between the condenser and the expansion valve.

[0013] Some machines for producing chilled food or drinks from ingredients in ingredient-containing pods include an evaporator of a refrigeration system defining a receptacle sized to receive the pod, the refrigeration system having a working fluid loop extending from the evaporator to a compressor, a condenser, an expansion valve or capillary tube, and back to the evaporator, the evaporator being made of a material having a thermal conductivity of at least 160 W / mk.

[0014] Some machines for producing chilled food or drinks from ingredients in ingredient-containing pods include an evaporator in a refrigeration system defining a receptacle sized to accommodate the pod, the refrigeration system having a working fluid loop extending from the evaporator to a compressor, a condenser, an expansion valve or capillary tube, and back to the evaporator, and the refrigerant is selected from the group consisting of R143A, R134a, R410a, R32 and R404a, carbon dioxide, ammonia, propane, and isobutane.

[0015] Some machines for producing chilled food or drinks from ingredients in ingredient-containing pods include an evaporator in a refrigeration system defining a receptacle sized to accommodate the pod, the refrigeration system having a working fluid loop extending from the evaporator to a compressor, a condenser, an expansion subsystem having multiple orifices or expansion devices connected in parallel, and back to the evaporator.

[0016] Some machines for producing chilled food or drinks from ingredients in ingredient-containing pods include an evaporator in a refrigeration system defining a receptacle sized to accommodate the pod, the refrigeration system having a working fluid loop extending from the evaporator to a compressor, a condenser, an expansion valve or capillary tube, a refrigerant line to pre-chill a reservoir, and back to the evaporator.

[0017] Some machines for producing chilled food or drinks from ingredients in ingredient-containing pods include an evaporator in a refrigeration system defining a receptacle sized to receive the pod, the refrigeration system having a working fluid loop extending from the evaporator to one side of a thermal battery, a compressor, a condenser, the other side of the thermal battery, an expansion valve or capillary tube, and back to the evaporator.

[0018] Implementations of these machines may include one or more of the following features.

[0019] In some embodiments, the machine also includes a bypass valve in the first bypass line.

[0020] In some embodiments, the machine also includes a second bypass line extending from the working fluid loop between the compressor and the condenser to the working fluid loop between the evaporator and the compressor. In some examples, the machine also includes a bypass valve in the second bypass line. In some examples, the machine also includes a suction line heat exchanger.

[0021] In some embodiments, the working fluid loop passes through a reservoir of phase change material disposed between the compressor and the condenser. In some examples, the phase change material is a mixture of ethylene glycol and water, salt water, paraffin wax, an alkane, or pure water, or combinations thereof. In some examples, the working fluid loop includes a pressure vessel between the condenser and the evaporator, a first isolation valve between the pressure vessel and the expansion valve, and a second isolation valve between the compressor and the condenser. In some examples, the working fluid loop passes through a thermoelectric cooler between the condenser and the expansion valve.

[0022] In some embodiments, the machine also includes an aluminum evaporator having a mass not exceeding 1.50 pounds.

[0023] In some embodiments, the machine has a pressure drop of less than 2 psi through the refrigeration system.

[0024] In some embodiments, the machine also includes up to 50 square inches of pod-to-evaporator heat transfer surface.

[0025] In some embodiments, the machine also includes an evaporator having cooling channels therein that allow for a mass rate of fluid of up to 180,000 lb / (ft2hr) and a refrigerant wetted area of ​​up to 200 in2.

[0026] In some embodiments, the machine also includes an evaporator refrigerant wetted area of ​​up to 200 square inches.

[0027] In some embodiments, the machine also includes an evaporator that clamps the pod.

[0028] In some embodiments, the machine also includes an evaporator having a copper inner wall adjacent to the pod.

[0029] In some embodiments, the machine also includes an evaporator constructed from microchannels.

[0030] The systems and methods described herein can provide many advantages. Some of these system embodiments and methods can provide a single serving of chilled food or drink. This approach can assist consumers in portion control. Some of these system embodiments and methods can provide consumers with the ability to choose a single serving of soft serve ice cream, for example. Some of these system embodiments and methods incorporate shelf-stable pods that do not require pre-cooling, pre-freezing or other preparation. Some of these system embodiments and methods can produce a frozen food or drink from a room temperature pod in under two minutes (and in some cases, under one minute). Some of these system embodiments and methods do not require any post-processing clean-up once the chilled or frozen food or drink has been produced. Some of these system embodiments and methods utilize recyclable aluminum pods.

[0031] The details of one or more embodiments of these systems and methods are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of these systems and methods will become apparent from the description and drawings, and from the claims. [Brief description of the drawings]

[0032] [Figure 1] 1A-1B: Fig. 1A is a perspective view of a machine for quickly cooling food and drinks. Fig. 1B shows the machine without the housing. [Figure 1C] FIG. 1B is a perspective view of a portion of the machine of FIG. 1A. [Diagram 2] Figures 2A-2D. Figure 2A is a perspective view of the machine of Figure 1A with the cover of the pod-machine interface shown transparent so that a more detailed schematic of the evaporator is visible. Figure 2B is a plan view of a portion of the machine without the housing and the pod-machine interface without the lid. Figures 2C and 2D are perspective and side plan views of the evaporator, respectively. [Diagram 3] 3A-3F show the components of the pod-machine interface operable to open and close the pod in the evaporator to dispense the produced food or drink. [Figure 4] FIG. 1 is a circuit diagram of a refrigeration system. [Diagram 5] 5A-5B are drawings of a capacitor prototype. [Figure 6A] FIG. [Figure 6B] FIG. 2 is a schematic side plan view of a pod and a mixing paddle disposed in the pod. [Figure 7A] FIG. 2 is a perspective view of a pod and associated drive shaft. [Figure 7B] FIG. 2 is a perspective view of a pod and associated drive shaft. [Figure 7C] 1 is a cross section of a portion of a pod with a drive shaft engaging a mixing paddle within the pod. [Figure 8]For ease of viewing, the first end of the pod is shown with its cap spaced apart from its base. [Figure 9] 9A-9G illustrate the rotation of the cap about the first end of the pod to open an aperture extending through the base. [Figure 10] FIG. 2 is an enlarged schematic side plan view of the pod; [Figure 11] 1 is a flow chart of a method of operating a machine to produce chilled food or drink. [Figure 12] FIG. 1 is a schematic diagram of a refrigeration system including an evaporator and expansion subsystem. [Figure 13] FIG. 1 is a schematic diagram of a refrigeration system including a bypass line to pre-chill a water tank upstream before the evaporator. [Figure 14] FIG. 1 is a schematic diagram of a refrigeration system including a thermal mass disposed between a compressor and a condenser. [Figure 15] FIG. 1 is a circuit diagram of a refrigeration system including a pressure vessel, a first control valve, and a second control valve. [Figure 16] FIG. 1 is a circuit diagram of a refrigeration system including a thermoelectric module. [Figure 17] 1 is a circuit diagram of a refrigeration system including a thermal battery, a first battery bypass valve, and a second battery bypass valve. [Figure 18] Figures 18A-B. Figure 18A is a plan view of the evaporator cover 127, and Figure 18B is a plan view of the evaporator body. [Figure 19] 19A-19B are perspective views of an evaporator with and without an associated lid. [Figure 20] 20A-20D. Schematic diagram of the flow path created by the channels of the evaporator and the associated lid. [Figure 21] 21A-21C are diagrams of an evaporator with a pod and a closing mechanism. [Figure 22] 22A-22B are side plan views of a closure mechanism including a first bolt and a second bolt. [Figure 23]23A-23H illustrate an evaporator with an extruded body. [Figure 24] 1 illustrates an evaporator incorporating an orifice plate. [Diagram 25] FIG. 19C is a perspective view of the evaporator shown in FIGS. 19A and 19B with an inner surface made of a different material than the evaporator. [Figure 26] 26A-26C are schematic diagrams of the cladding. [Figure 27] 1 is an exemplary drawing of a material containing microchannels. [Figure 28] 28A-28C are plan views of a rotary compressor. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] Like reference symbols in the various drawings indicate like elements.

[0034] This specification describes systems and methods for rapidly chilling food and drinks. Some of these systems and methods use countertop or stationary machines to chill food and drinks in containers from room temperature to frozen in less than two minutes. For example, the approach described herein has successfully demonstrated the ability to make soft serve ice cream, frozen coffee, frozen smoothies, and frozen cocktails from room temperature pods in approximately 90 seconds. This approach can also be used to chill cocktails, make frozen smoothies, frozen protein and other functional drink shakes (e.g. collagen-based, energy, plant-based, non-dairy, CBD shakes), frozen and chilled coffee drinks with and without nitrogen therein, make hard ice cream, make milkshakes, make frozen yogurt and chilled probiotic drinks. These systems and methods are based on a pod-machine interface that provides a refrigeration cycle with fewer activations and is easy to use and highly efficient heat transfer. Some of the pods described can be sterilized (eg, using retort sterilization) and used to store, for example, dairy-containing ingredients at room temperature for up to 18 months.

[0035] FIG. 1A is a perspective view of a machine 100 for cooling food or drinks. FIG. 1B shows the machine without the housing. The machine 100 reduces the temperature of ingredients in pods that contain the ingredients. Most pods include a mixing paddle that is used to mix the ingredients before dispensing the cooled or frozen product. The machine 100 includes a body 102 with a housing 104 and a pod-machine interface 106. The body 102 includes a compressor, a condenser, a fan, an evaporator, a capillary tube, a control system, a lid system, and a dispensing system. The pod-machine interface 106 includes an evaporator 108 of a refrigeration system 109 with other components located inside the housing 104. As shown in FIG. 1B, the evaporator 108 defines a receptacle 110 sized to accommodate a pod.

[0036] The lid 112 is attached to the housing 104 by a hinge 114. The lid 112 can rotate between a closed position (FIG. 1A) covering the receptacle 110 and an open position (FIG. 1B) exposing the receptacle 110. In the closed position, the lid 112 covers the receptacle 110 and is locked in place. In the machine 100, a latch 116 on the lid 112 engages a latch recess 118 in the pod-machine interface 106. A latch sensor 120 is disposed in the latch recess 118 and determines whether the latch 116 is engaged in the latch recess 118. A processor 122 is electronically connected to the latch sensor 120 and recognizes that the lid 112 is closed when the latch sensor 120 determines that the latch 116 and the latch recess 118 are engaged.

[0037] When the lid 112 moves from its closed position to its open position, the auxiliary cover 115 rotates upward. Some auxiliary covers slide into the housing when the lid moves to the open position.

[0038] In the machine 100, the evaporator 108 is fixed in place relative to the body 102 of the machine 100, and movement of a lid 112 provides access into the receptacle 110. In some machines, the evaporator 108 is movable relative to the body 102, and movement of the evaporator 108 provides access into the receptacle 110.

[0039] A motor 124 disposed in the housing 104 is mechanically connected to a drive shaft 126 extending from the lid 112. When the lid 112 is in its closed position, the drive shaft 126 extends into the receptacle 110 and engages a pod, if one is present, to move one or more paddles in the pod. A processor 122 is in electronic communication with the motor 124 to control its operation. In some machines, a shaft associated with the pod's paddle(s) extends outwardly from the pod, and the lid 112 has a rotating receptacle (instead of the drive shaft 126) that is mechanically connected to the motor 124.

[0040] FIG. 1C is a perspective view of the lid 112, shown in isolation so that the belt 125 extending from the motor 124 to the drive shaft 126 can be seen. Referring again to FIG. 1B, the motor 124 is mounted to a plate that runs along rails 127. The plate can be moved approximately 0.25 inches to adjust the tension in the belt. During assembly, the plate slides along the rails. A spring disposed between the plate and the lid 112 biases the lid 112 away from the plate, maintaining tension in the belt.

[0041] FIGURE 2A is a perspective view of the machine 100 with the cover of the pod-machine interface 106 shown transparent to allow a more detailed view of the vaporizer 108. FIGURE 2B is a plan view of a portion of the machine 100 without the housing 104 and the pod-machine interface 106 without the lid 112. FIGURES 2C and 2D are perspective and side plan views, respectively, of the vaporizer 108. Other pod-machine interfaces are described in more detail in U.S. Patent Application No. ______ (Attorney Docket No. 47354-0009001), which has been filed concurrently herewith and the disclosure of which is incorporated herein by reference in its entirety.

[0042] The evaporator 108 has a clamshell configuration with a first portion 128 attached on one side to a second portion 130 by a living hinge 132 and separated on the other side by a gap 134. Refrigerant flows from other components of the refrigeration system through fluid channels 136 to the evaporator 108 (best seen in FIG. 2B). The refrigerant flows through the first portion 128, the living hinge 132, and the second portion 130 in an internal channel through the evaporator 108.

[0043] The space 137 (best seen in FIG. 2B ) between the outer wall of the evaporator 108 and the inner wall of the casing of the pod-machine interface 106 is filled with insulation to reduce heat exchange between the surrounding environment and the evaporator 108. In the machine 100, the space 137 is filled with aerogel (not shown). Some machines use other insulation, such as an annulus (such as an air space), insulating foam made from various polymers or fiberglass wool.

[0044] The evaporator 108 has an open position and a closed position. In the open position, the gap 134 opens to provide an air gap between the first portion 128 and the second portion 130. In the machine 100, the first portion 128 and the second portion 130 are pressed together in the closed position. In some machines, in the closed position, the first portion and the second portion are pressed toward each other and the gap is reduced but still defined by the space between the first portion and the second portion.

[0045] The inside diameter ID of the evaporator 108 is slightly larger in the open position than in the closed position. Pods can be inserted and removed into the evaporator 108 while the evaporator is in the open position. The transition of the evaporator 108 from its open position to its closed position after the pod is inserted causes the evaporator 108 to clamp tightly around the outside diameter of the pod. For example, the machine 100 is configured to use pods with an outside diameter of 2.085 inches. The evaporator 108 has an inside diameter of 2.115 inches in the open position and an inside diameter of 2.085 inches in the closed position. Some machines have evaporators so configured that are sized to cool other pods. The pods can be made from commercially available can sizes. For example, cans can be made from "slim" cans with diameters ranging from 2.080" to 2.090" and volumes ranging from 180 milliliters (ml) to 300 ml, "sleek" cans with diameters ranging from 2.250" to 2.400" and volumes ranging from 180 ml to 400 ml, and "standard" size cans with diameters ranging from 2.500" to 2.600" and volumes ranging from 200 ml to 500 ml. Machine 100 is configured to use pods with an outside diameter of 2.085 inches. Evaporator 108 has an inside diameter of 2.115 inches in its open position and an inside diameter of 2.085 inches in its closed position. Some machines have evaporators so configured that are sized to cool other pods.

[0046] The closed position of the evaporator 108 improves heat transfer between the inserted pod 150 and the evaporator 108 by increasing the contact area between the pod 150 and the evaporator 108 and reducing or eliminating the air gap between the walls of the pod 150 and the evaporator 108. In some pods, the pressure exerted on the pod by the evaporator 108 is countered by mixing paddles, pressurized gas within the pod, or both, to maintain the pod's casing shape.

[0047] In the evaporator 108, the relative positions of the first and second portions 128, 130 and the size of the gap 134 between them are controlled by two rods 138 connected by a bolt 140 and two springs 142. Each of the rods 138 has a central threaded hole through which the bolt 140 extends and two end holes that engage a pin 144. Each of the two springs 142 is disposed around the pin 144 that extends between the rods 138. Some machines use other systems, such as a perimeter cable system with a cable that extends around the outside diameter of the evaporator 108, to control the size of the gap 134. Tightening the cable closes the evaporator 108 and loosening it opens the evaporator 108. Other evaporators have multiple bolts and end holes, one or more springs, and one or more engaging pins.

[0048] One rod 138 is attached to the first portion 128 of the evaporator 108 and the other rod 138 is attached to the second portion 130 of the evaporator 108. In some evaporators, the rod 138 is integral with the body of the evaporator 108 rather than being attached to the body of the evaporator. A spring 142 urges the rods 138 away from each other. The spring urges the first portion 128 and the second portion 130 of the evaporator 108 away from each other at the gap 134. Rotating the bolt 140 in one direction increases the force pushing the rods 138 toward each other, and rotating the bolt in the opposite direction decreases this force. When the force exerted by the bolt 140 is greater than the force of the spring, the rod 138 brings the first portion 128 and the second portion 130 of the evaporator closer together.

[0049] The machine 100 includes an electric motor 146 (shown in FIG. 2B) operable to rotate the bolt 140 to control the size of the gap 134. Some machines use other mechanisms to rotate the bolt 140. For example, some machines use a mechanical linkage between the lid 112 and the bolt 140 to rotate the bolt 140 as the lid 112 is opening and closing. Some machines include a handle that can be attached to the bolt to manually tighten or loosen the bolt. Some machines have a wedge system that urges a rod into a closed position when the machine's lid is closed. This approach may be used in place of the electric motor 146 or may be provided as a backup in case the motor fails.

[0050] The electric motor 146 communicates with and is controlled by the processor 122 of the machine 100. Some electric drives include a torque sensor that transmits torque measurements to the processor 122. The processor 122 sends a signal to the motor to rotate the bolt 140 in a first direction to press the rods 138 together, for example, when the pod sensor indicates that a pod has been placed in the receptacle 110 or when the latch sensor 120 indicates that the lid 112 and pod-machine interface 106 are engaged. It is desirable to close the clamshell evaporator to hold the pod in a rigid, fixed position before the lid is closed and the shaft penetrates the pod and engages the mixing paddle. This positioning can be important for the engagement of the drive shaft with the mixing paddle. The processor 122 can, for example, after the food or drink being produced has been cooled or frozen and dispensed from the machine 100, send a signal to the electrical drive to rotate the bolt 140 in a second direction to open the evaporator gap 134 and facilitate removal of the pod 150 from the evaporator 108.

[0051] The base of the evaporator 108 has three holes 148 (see FIG. 2C) that are used to mount the evaporator 108 to the floor of the pod-machine interface 106. All three holes 148 extend through the second portion 130 of the base of the evaporator 108. The first portion 128 of the evaporator 108 is not directly attached to the floor of the pod-machine interface 106. This configuration allows for the opening and closing motions described above. Other configurations that allow for the opening and closing motion of the evaporator 108 may also be used. Some machines have more or less than three holes 148. Some evaporators are mounted to components other than the floor of the pod-machine interface, such as a dispensing mechanism.

[0052] Many factors affect the performance of a refrigeration system. Important factors include the mass velocity of the refrigerant flowing through the system, the refrigerant wetted area, the refrigeration process, the area of ​​the heat transfer surface between the pod and the evaporator, the mass of the evaporator, and the thermal conductivity of the heat transfer surface material. Extensive modeling and empirical studies in the development of the prototype system described herein determined that the proper selection of a balance between the mass velocity of the refrigerant flowing through the system and the refrigerant wetted area is the most critical parameter for providing a system capable of freezing up to 12 ounces of confectionery in under 2 minutes.

[0053] The evaporators described herein can have the following characteristics: [Table 1] The following paragraphs describe in more detail the importance of these parameters.

[0054] Mass velocity is comprised of the multiple phase nature or refrigerant flowing through the evaporator. The two-phase process utilizes the high amount of heat absorbed and consumed when the refrigerant fluid (R-290 propane, for example) changes state from liquid to gas and gas to liquid, respectively. The heat transfer rate is determined in part by the evaporator inner surface, which is in contact with the novel liquid refrigerant to evaporate and cool the liquid ice cream mix. For this, the velocity of the refrigerant fluid must be high enough to force the vapor down the center of the channels or passages inside the evaporator walls and to force the liquid refrigerant through these channel passages inside the walls. One rough measurement of fluid velocity in a refrigeration system is the mass velocity, which is expressed in lb / hr·ft 2 It is the mass flow rate of refrigerant in a system per unit cross-sectional area of ​​the flow passage, in units of ft / s. Velocity, measured in ft / s (better known as a measure of "velocity"), is difficult to apply to two-phase systems because velocity (ft / s) constantly changes as the fluid flow changes state from liquid to gas. If the liquid refrigerant constantly spreads across the walls of the evaporator, it may evaporate, and new liquid may be forced against the walls of the cooling channel by a "core" of vapor flowing down the center of the passage. At low velocities, the flow separates based on gravity, with the liquid remaining at the bottom of the cooling passage inside the evaporator and the vapor rising to the top of the cooling passage channel. If the surface area exposed to the liquid is reduced by half, for example, the amount of heat transfer may be cut almost in half. According to the American Society of Heating, Refrigeration and Air-Conditioning Engineers (ASHRAE), 150,000 lb / hr·ft 2A mass velocity of 0.1 mm maximizes the performance of the majority of evaporator flow passages. Mass velocity is one of the parameters that must be balanced to optimize a refrigerant system. Parameters that affect evaporator performance include mass flow rate, convective heat transfer rate, and pressure drop. The nominal operating pressure of the evaporator is determined by the required evaporator temperature and the properties of the refrigerant used in the system. The mass flow rate of the refrigerant through the evaporator needs to be high enough to absorb the amount of heat energy of the confectionery in a given time and freeze it. The mass flow rate is determined primarily by the size of the compressor. To reduce cost, weight, and size, it is desirable to use the smallest viable compressor. The convective heat transfer rate is affected by the mass velocity and the wetted area of ​​the evaporator. The convective heat transfer rate increases with increasing mass velocity. However, pressure drop also increases with mass velocity. This in turn increases the power required to operate the compressor and reduces the mass flow rate that the compressor can deliver. It is desirable to design an evaporator that meets performance goals while using the smallest, least expensive viable compressor. It has been determined that an evaporator with a mass velocity of 75,000-125,000 lb / hr ft^2 is effective in helping to provide a system capable of freezing up to 12 oz of confectionery in under 2 minutes. The latest prototype has a mass velocity of approximately 100,000 lb / hr ft^2, which strikes a good balance between high mass velocity, manageable pressure drop in the system, and a reasonably sized compressor.

[0055] Another important factor affecting the performance of an evaporator is the area wetted by the refrigerant, which is the area of ​​all cooling channels in the evaporator that are exposed to the refrigerant. Increasing the wetted area can improve the heat transfer characteristics of the evaporator. However, increasing the wetted area increases the mass of the evaporator, which increases the thermal inertia and can worsen the heat transfer characteristics of the evaporator.

[0056] The amount of heat that can be transferred from the liquid in the pod to the outside is proportional to the area of ​​the heat transfer surface between the pod and the evaporator. A larger area is desirable, but increasing the area may require increasing the mass of the evaporator which may compromise the heat transfer characteristics of the evaporator. It has been determined that an evaporator having a pod-to-evaporator heat transfer surface area of ​​20 to 40 square inches effectively combines with other characteristics to assist in providing a system capable of freezing up to 12 ounces of confectionery in under two minutes.

[0057] Thermal conductivity is an inherent property of a material related to its ability to conduct heat. Heat transfer by conduction generally involves the transfer of energy within a material when it is not in motion. Evaporators with walls made of a material with high conductivity (aluminum, for example) reduce the temperature difference across the walls of the evaporator. This reduction in temperature difference reduces the amount of work required by the refrigeration system to cool the evaporator to a precise temperature.

[0058] In order for the desired heat transfer to occur, the evaporator must be cooled. The greater the mass of the evaporator, the longer this cooling takes. Reducing the mass of the evaporator reduces the amount of material that needs to be cooled during the freezing cycle. A larger mass evaporator increases the time required to freeze up to 12 ounces of confectionery.

[0059] The effects of thermal conductivity and mass can be balanced by proper selection of materials. There are materials such as copper that have a higher thermal conductivity than aluminum. However, the density of copper is greater than that of aluminum. For this reason, some evaporators have been constructed using the highly thermally conductive copper only on the heat exchange surfaces of the evaporator and aluminum everywhere else.

[0060] 3A-3F show components of the pod-machine interface 106 that are operable to open the pod in the evaporator 108 and dispense the food or drink produced by the machine 100. This is an example of one approach to opening the pod, although some machines and associated pods use other approaches.

[0061] FIG. 3A is a schematic, partially cut away view of the pod-machine interface 106 with the pod 150 installed in the evaporator 108. FIG. 3B is a schematic, top view looking upwards showing the relationship between the end of the pod 150 and the floor 152 of the pod-machine interface 106. The floor 152 of the pod-machine interface 106 is formed by a dispenser 153. FIGS. 3C and 3D are perspective views of the dispenser 153. FIGS. 3E and 3F are perspective views of an insert 154 disposed in the dispenser 153. The insert 154 includes an electric motor 146 operable to drive a worm gear 157 and the floor 152 of the pod-machine interface 106. The worm gear 157 engages a gear 159 having an annular configuration. An annular member 161 attached to the gear 159 extends from the gear 159 into an interior region of the pod-machine interface 106. The ring member 161 has protrusions 163 configured to engage and open a pod inserted into the pod-machine interface 106. The protrusions 163 of the ring member 161 are four dowel-shaped protrusions. Some ring gears may have more or fewer protrusions and may have other shapes, e.g., a "tooth shape."

[0062] The pod 150 includes a body 158 containing a mixing paddle 160 (see FIG. 3A). The pod 150 also has a base 162 defining an aperture 164 and a cap 166 extending across the base 162 (see FIG. 3B). The base 162 is spliced ​​or secured to the body 158 of the pod 150. The base 162 includes a protrusion 165. The cap 166 mounted on the base 162 is rotatable about the circumference or axis of the pod 150. In use, when the product from the pod 150 is ready to be dispensed, the machine's dispenser 153 engages the cap 166 and rotates it around the end of the first pod 150. The cap 166 rotates to an engaged position and then separates the protrusion 165 from the remainder of the base 162. The pod 150 and its components are described in more detail with respect to Figures 6A-10.

[0063] An aperture 164 in the base 162 is opened by rotation of the cap 166. The pod-machine interface 106 includes an electric motor 146 having threads that engage the outer periphery of a gear 168. Operation of the electric motor 146 rotates the gear 168. The gear 168 is attached to an annular member 161 such that rotation of the gear 168 rotates the annular member 161. The gear 168 and the annular member 161 are both annular and define a central hole through which food or drink can pass through the aperture 164 and be dispensed from the pod 150 without contacting the gear 168 or the annular member 161. When the pod 150 is installed in the evaporator 108, the annular member 161 engages the cap 166 such that rotation of the annular member 161 rotates the cap 166.

[0064] 4 is a circuit diagram of a refrigeration system 109 including an evaporator 108. The refrigeration system also includes a condenser 180, a suction line heat exchanger 182, an expansion valve 184, and a compressor 186. High pressure liquid refrigerant flows from the condenser 180 through the suction line heat exchanger 182 and the expansion valve 184 to the evaporator 108. The expansion valve 184 restricts the flow of liquid refrigerant fluid, lowering the pressure of the liquid refrigerant as it leaves the expansion valve 184. The low pressure liquid and vapor mixture then travels to the evaporator 108 where heat absorbed from the pods 150 and the contents within the evaporator 108 changes the refrigerant from a liquid and vapor mixture to a gas. The vapor phase refrigerant flows from the evaporator 108 through the suction line heat exchanger 182 to the compressor 186. In the suction line heat exchanger 182, low temperature vapor leaving the evaporator 108 pre-cools the liquid leaving the condenser 180. The refrigerant enters the compressor 186 as a low pressure gas and leaves the compressor 186 as a high pressure gas. The gas then flows to the condenser 180 where heat exchange cools and condenses the refrigerant to a liquid.

[0065] The refrigeration system 109 includes a first bypass line 188 and a second bypass line 190. The first bypass line 188 connects directly between the compressor 186 discharge and the compressor 186 inlet. Bypass valves are disposed in both the first and second bypass lines to open and close passages to allow refrigerant to flow through the bypass. By diverting refrigerant directly from the compressor discharge to the inlet, evaporator defrosting and temperature control can be provided without injecting hot gas into the evaporator. The first bypass line 188 also provides a means for rapid pressure equalization across the compressor 186, allowing for rapid restart (i.e., freezing one pod followed quickly by the next pod). The second bypass line 190 allows for the application of warm gas to the evaporator 108 to defrost the evaporator 108. The bypass valves may be, for example, electromagnetic solenoid valves or throttling valves.

[0066] Figures 5A and 5B are drawings of a prototype of a condenser 180. The condenser has internal channels 192 that increase the area to interact with the refrigerant which cools it quickly. These images show microchannel tubing, which is used because it has small channels that maintain the velocity of the coolant, is thin-walled for good heat transfer, and has less mass to prevent the condenser from becoming a heat sink.

[0067] Figures 6A and 6B show an embodiment of a pod 150 for use with the machine 100 described with respect to Figures 1A-3F. Figure 6A is a side plan view of the pod 150. Figure 6B is a schematic side plan view of the pod 150 and a mixing paddle 160 disposed within the body 158 of the pod 150. Other pod-machine interfaces that can be used herewith, and similar machines, are described in more detail in U.S. Patent Application No. ______ (Attorney Docket No. 47354-0010001), which has been filed concurrently herewith, the disclosure of which is incorporated herein by reference in its entirety.

[0068] The pod 150 is sized to fit into the receptacle 110 of the machine 100. The pod can be sized to provide a single serving of the produced food or drink. Typically, the pods have a volume of between 6 and 18 fluid ounces. The pod 150 has a volume of approximately 8.5 fluid ounces.

[0069] The body 158 of the pod 150 is a canister containing a mixing paddle 160. The body 158 extends from a first end 210 at the base to a second end 212 and has a circular cross section. The first end 210 has a diameter D at the second end 212. LE Diameter D is slightly larger than UE This configuration facilitates stacking multiple pods 200 on top of each other, with the first end 210 of one pod receiving the second end 212 of another pod.

[0070] A wall 214 connects the first end 210 and the second end 212. The wall 214 has a first neck 216, a second neck 218, and a cylindrical portion 220 between the first neck 216 and the second neck 218. The cylindrical portion 220 has a diameter D B It has a circular cross section of diameter D B is the diameter D of the first end 210 UE and the diameter D of the second end 212 LE A first neck 216 connects the cylindrical portion 220 to the first end 210 and has a smaller diameter D UE to the larger diameter D of the cylindrical portion 220 B The second neck 218 connects the cylindrical portion 220 to the second end 212 and tapers as it extends to the larger diameter D B The diameter D of the second end 212 is smaller than the LE Because second end 212 has a smaller diameter than first end 210, second neck 218 tapers more steeply than first neck 216.

[0071] This configuration of pod 150 allows for increased material usage, i.e., the ability to use more base material (e.g., aluminum) per pod. This configuration also contributes to the columnar strength of the pod.

[0072] The pod 150 is designed for good heat transfer from the evaporator to the pod's contents. The body 158 of the pod 150 is made of aluminum and is 5-50 microns thick. Some pod bodies are made of other materials, such as tin, stainless steel, and various polymers, such as polyethylene terephthalate (PTE).

[0073] The pod 150 may be made from a combination of various materials that contribute to the manufacturability and performance of the pod. In one embodiment, the walls and second end 212 of the pod may be made from 3104 aluminum and the base may be made from 5182 aluminum.

[0074] In some pods, the internal components of the pod are coated with a lacquer to prevent corrosion of the pod when in contact with the ingredients contained within the pod. This lacquer also reduces the possibility of "off-notes" of metals in the food and beverage ingredients contained within the pod. For example, pods made of aluminum may be coated internally with one or a combination of Sherwin Williams / Valspar V70Q11, V70Q05, 32SO2AD, 40Q60AJ, PPG Innovel 2012-823, 2012-820C, and / or Akzo Nobel Aqualure G1.50. Other coatings made by the same or other coating manufacturers may also be used.

[0075] Some mixing paddles are made of similar aluminum alloys and coated with a similar lacquer or coating material. For example, Whitford / PPG coating 8870 may be used as the mixing paddle coating. The mixing paddle lacquer may have the added benefit of being stain-resistant and hardening to the mixing paddle.

[0076] 7A-7C illustrate the engagement between the drive shaft 126 of the machine 100 and the mixing paddle 160 of the pod 150 inserted into the machine 100. FIGS. 7A and 7B are perspective views of the pod 150 and the drive shaft 126. In use, the pod 150 is inserted into the receptacle 110 of the vaporizer 108 such that the first end 210 of the pod 150 is downward. As shown in FIG. 7A, this positioning exposes the second end 212 of the pod 150 to the drive shaft 126. When the lid 112 is closed (see FIG. 1A), the drive shaft 126 is pressed against the second end 212 of the pod 150 with sufficient force to cause the drive shaft 126 to penetrate the second end 212 of the pod 150. FIG. 7B shows the resulting hole exposing the mixing paddle 160 along with the drive shaft 126, offset for ease of visualization. 7C is a cross section of a portion of the pod 150 with the drive shaft 126 engaging the mixing paddle 160 after the lid has been closed. Typically, there is no tight seal between the drive shaft 126 and the pod 150 so that air can flow therethrough as the frozen confection is expelled or dispensed from the other end of the pod 150. In an alternative embodiment, the pod 150 has a tight seal to maintain pressure and improve contact between the pod 150 and the evaporator 108.

[0077] Some mixing paddles contain a funnel or receptacle arrangement that receives the perforated end of the second end of the pod when the second end is perforated by the drive shaft.

[0078] Figure 8 shows the first end 210 of the pod 150 with the cap 166 spaced from the base 162 for ease of viewing. Figures 9A-9D illustrate the rotation of the cap 166 about the first end 210 of the pod 150, cutting and carrying away the protrusion 165 of the base 162 to reveal the aperture 164 extending through the base 162.

[0079] The base 162 is manufactured separately from the body 158 of the pod 150 and then attached (e.g., by crimping or seaming) to the body 158 of the pod 150 to cover the open end of the body 158. The projection 165 of the base 162 can be formed, for example, by stamping, deep drawing, or heading the aluminum sheet used to form the base. The projection 165 is attached to the remainder of the base 162, for example, by weakened score lines 173. The scoring can be vertical scores into the base of the aluminum sheet or horizontal scores into the wall of the projection 165. For example, the material can be scored to have an initial thickness of 0.008 inches to 0.010 inches and a thickness of 0.001 inches to 0.008 inches after scoring. In an alternative embodiment, there is no scoring after stamping, and the walls are intentionally thinned to facilitate fracturing. In another variation, the wall thickness does not change, and the force of the cap 166 combined with the force of engagement with the dispensing mechanism of the machine is sufficient to cut the wall thickness at the projection 165 to 0.008 inches to 0.010 inches. Scoring allows the projection 165 to be lifted and sheared off the base 162 with a force of 5 to 75 pounds, for example 15 to 40 pounds.

[0080] The cap 166 has a first aperture 222 and a second aperture 224. The first aperture roughly matches the shape of the aperture 164. The aperture 164 is exposed when the protrusion 165 is removed and extends through the base 162. The second aperture 224 has a shape corresponding to two overlapping circles, one of which has a shape corresponding to the shape of the protrusion 165 and the other of which is slightly smaller. A ramp 226 extends between the outer edges of the two overlapping circles. At the top where the ramp transitions, there is an additional 0.020 inches of material thickness. As will be described in more detail with reference to Figures 9A-9G, this additional height assists in lifting the head of the protrusion to break and open the aperture during rotation of the cap.

[0081] As shown in Figures 9A and 9B, the cap 166 is initially attached to the base 162 in alignment with the projection 165 and extends through the larger of the overlapping circles of the second aperture 224. As shown in Figures 9C and 9D, when the machine's processor 122 activates the electric motor 146 to rotate the gear 168 and the annular member 161, the rotation of the cap 166 causes the ramp 226 to slide under the lip of the projection 165. Continued rotation of the cap 166 applies a lifting force that separates the projection 165 from the remainder of the base 162 (see Figures 9E-9G), and then the first aperture 222 of the cap 166 aligns with the aperture 164 in the base 162 that results from the removal of the projection 165.

[0082] Some pods include structure for maintaining the projection 165 after it is separated from the base 162. In the pod 150, the projection 165 has a head 167, a stem 169, and a lower portion 171 (best seen in FIG. 9G). The stem 169 extends between the head 167 and the lower portion 171 and has a smaller cross section than the head 167 and the lower portion 171. When rotation of the cap 166 causes the projection 165 to separate from the remainder of the base 162, the cap 166 presses the stem 169 laterally along one edge of the overlapping circles of the second aperture 224, with the head 167 and the lower portion 171 bracketing the cap 166. This configuration maintains the projection 165 as it separates from the base 166. Such a configuration reduces the likelihood of the projection 165 dropping into an awaiting receptacle when it is removed from the base.

[0083] Some pods include other approaches for separating the projection 165 from the remainder of the base 162. For example, in some pods, the base has a rotatable cutting mechanism riveted to the base. The rotatable cutting mechanism has a similar shape as described with respect to the cap 166, but this secondary component is riveted and positioned immediately around the base 162, rather than mounted on and around the base. Once the refrigeration cycle is complete, the machine's processor 122 activates the machine's arms to rotate the riveted cutting mechanism around the rivet. During rotation, the cutting mechanism engages, cuts, and carries away the projection 165, leaving the aperture 164 of the base 162 in its place.

[0084] In another embodiment, some pods have a cap with a sliding knife that moves across the base to remove the protrusions. The sliding knife is mechanically actuated and when triggered by a controller, slides across the base to separate, remove, and collect the protrusions 165. The cap 166 has a guillotine feature that when actuated by a machine, can slide linearly across and upwards the base 162. The cap 166 engages, severs, and carries away the protrusions 165. In another embodiment, the guillotine feature may be located at the center of the machine rather than in the cap 166 of the pod 150. In another embodiment, the guillotine feature may be mounted as a secondary component within the base 162 rather than a secondary mounted component as in the example with the cap 166.

[0085] Some pods have a dispensing mechanism that includes a lift-up style that can be engaged and disengaged by a machine. Once the refrigeration cycle is complete, a machine arm engages a tab on the pod and lifts it, pressing and piercing the base to create an aperture in the base. The chilled or frozen product is dispensed through the aperture. During dispensing, the perforated side of the base remains hinged to the base and remains inside the pod. The mix rotates around or over the perforated side, or in another embodiment, the mixing paddle continues to rotate out of the way. In some lift-up styles, a machine arm separates the perforated side from the base.

[0086] 10 is an enlarged schematic side plan view of a pod 150. The mixing paddle 160 includes a central stem 228 and two blades 230 extending from the central stem 228. The blades 230 are helical blades shaped to agitate the contents of the pod 150 and to remove ingredients adhering to the inside surface of the body 158 of the pod 150. Some mixing paddles have a single blade and some have three or more blades.

[0087] Fluid (e.g., liquid ingredients, air, or frozen confectionery) flows through the openings 232 in the blades 230 as the mixing paddle 160 rotates. These openings reduce the force required to rotate the mixing paddle 160. This reduction can be significant when the viscosity of the ingredients increases (for example, when forming ice cream). The openings 232 also aid in mixing and aeration of the ingredients within the pod.

[0088] The outer edges of the blades 230 define slots 234. The slots 234 are offset from one another to remove ingredients from a majority of the inner surface of the body 158 that are applied to the inner surface of the body by one of the blades 230 as the mixing paddle 160 rotates. The mixing paddle 160 is wider than the first end 210 of the body 158 of the pod 150, but the slots 234 are staggered to facilitate insertion of the mixing paddle 160 into the body 158 of the pod 150 such that the slots 234 align with the first end 210 by rotating the mixing paddle 160 during insertion. In another embodiment, the outer diameter of the mixing paddle is less than the diameter of the opening of the pod 150 to allow for linear (non-rotating) insertion into the pod 150. In another embodiment, one of the blades in the mixing paddle has a wider outer diameter than the diameter of the other blade, thus allowing for linear (non-rotating) insertion into the pod 150. In this mixing paddle configuration, one blade is intended to remove (e.g., scrape) ingredients from the side wall, while the other blade, which has a shorter diameter, is intended to perform a stronger mixing action.

[0089] Some mixing paddles have one or more blades hinged to a central stem. During insertion, the blades are hinged to a contracted configuration and can be released to an expanded configuration as soon as they are inserted. Some hinged blades are fixed open while rotating in a first direction and can fold when rotating in a second direction opposite the first direction. Some hinged blades are fixed once inside the pod, regardless of rotation direction, and are locked in an outward position. Some hinged blades are manually contracted, expanded, and locked.

[0090] The mixing paddle 160 rotates clockwise to remove accumulated frozen confectionery from the walls 214 of the pod. Gravity drives the removal of confectionery that falls from the walls of the pod to the first end 210. As the mixing paddle 160 rotates in a counterclockwise direction, it lifts and agitates ingredients towards the second end 212. As the paddle changes direction and rotates clockwise, ingredients are pushed towards the first end 210. As shown and described with respect to FIG. 9D, when the protrusion 165 of the base 162 is removed, the clockwise rotation of the mixing paddle dispenses the produced food or drink from the pod 150 through the aperture 164. Some paddles mix and dispense the contents of the pod by rotating in a first direction. Some paddles mix by moving in a first direction and a second direction, and dispense by moving in the second direction when the pod is opened.

[0091] The central stem 228 defines a recess 236 sized to receive the drive shaft 126 of the machine 100. The recess and drive shaft 126 have a square cross-section such that the drive shaft 126 and mixing paddle 160 are rotatably constrained. When the motor rotates the drive shaft 126, the drive shaft rotates the mixing paddle 160. In some embodiments, the cross-section of the drive shaft is of various shapes and the cross-section of the recess is formed to match. In some examples, the drive shaft and the recess are threadedly connected. In some pods, the recess contains a mating structure to grip the drive shaft and rotationally couple the drive shaft and the paddle.

[0092] 11 is a flow chart of a method 250 implemented in processor 122 to operate machine 100. Method 250 is described with reference to refrigeration system 109 and machine 100. Method 250 may be used with other refrigeration systems and machines. Method 250 is described as producing soft serve ice cream, but may also be used to produce other chilled or frozen drinks and foods.

[0093] The first step of the method 250 is to start the machine 100 (step 260) and start the fans associated with the compressor 186 and the condenser 180 (step 262). The refrigeration system 109 is then idled at the regulated temperature (step 264). In the method 250, the temperature of the evaporator 108 is controlled to remain at approximately 0.75°C, but may vary by ±0.25°C. Some machines are operated at other idle temperatures, for example, 0.75°C to room temperature (22.0°C). If the evaporator temperature is below 0.5°C, the processor 122 opens the bypass valve 190 to increase heat in the system (step 266). If the evaporator temperature is above 1°C, the bypass valve 190 is closed to cool the evaporator (step 268). From the idle state, the machine 100 can be operated to produce ice cream (step 270) or turned off (step 272).

[0094] After inserting the pod, the user presses the start button. When the user presses the start button, the bypass valve 190 closes, the evaporator 108 moves to its closed position, and the motor 124 starts (step 274). In some machines, the evaporator is closed electronically using a motor. In some machines, the evaporator is closed mechanically, for example, by a lid moving from an open position to a closed position. In some systems, a sensor recognizes that a pod 150 is present in the evaporator 108 before these actions are taken.

[0095] Some systems include radio frequency identification (RFID) or other intelligent bar codes such as UPC bars or QR codes. The identification information in the pod can be used to trigger specific cooling and blending algorithms for the particular pod. These systems can selectively read the RFID, QR code or bar code to identify the blending motor speed profile and blending motor torque thresholds (step 273).

[0096] The identification information can also be used to facilitate direct consumer marketing (e.g., over the Internet or using a subscription model). The approach and system described herein allows for the sale of ice cream through e-commerce as the pods are shelf stable. In a subscription model, a customer pays a monthly fee for a set number of pods delivered each month. The customer can select a personalized pod from a variety of categories (e.g., ice cream, healthy smoothie, frozen coffee, or frozen cocktail) and also select a personalized flavor (e.g., chocolate or vanilla).

[0097] The identification can also be used to track each pod used. In some systems, the machine can be linked to a network and configured to notify the vendor which pods have been used and which need to be replaced (e.g., during a weekly delivery). This method is more efficient than having the consumer go to the grocery store to purchase the pods.

[0098] These actions cool the pod 150 in the evaporator 108 while rotating the mixing paddle 160. The viscosity of the contents of the pod 150 increases as ice cream forms. A torque sensor in the machine measures the torque of the motor 124 required to rotate the mixing paddle 160 in the pod 150. When the torque of the motor 124 measured by the torque sensor meets a predetermined threshold, the machine 100 operates in a dispense mode (276). The dispense port opens and the motor 124 reverses direction (step 278), pushing the frozen confection out of the pod 150. This continues for approximately 1-10 seconds to dispense the contents of the pod 150 (step 280). The machine 100 then switches to a defrost mode (step 282). Frost buildup on the evaporator 108 can reduce the heat transfer efficiency of the evaporator 108. In addition, the evaporator 108 may freeze the pod 150, the first and second portions 128 and 130 of the evaporator may both freeze, and / or the pod may freeze the evaporator. The evaporator may be defrosted between cycles to avoid these issues by opening the bypass valve 170, opening the evaporator 108, and stopping the motor 124 (step 282). The machine then defrosts the evaporator by diverting gases through the bypass valve for approximately 1-10 seconds (step 284). The machine is programmed to defrost after each cycle unless the thermocup indicates that the evaporator 108 is already above freezing. The pod may then be removed. The machine 100 then returns to idle mode (step 264). In some machines, a thermometer measures the temperature of the contents of the pod 150 to identify the time to dispense the contents of the pod. Some machines initiate the dispense mode when the predetermined time is reached. In some machines, a combination of the torque required to rotate the mixing paddle, the current draw of the mixing motor, the temperature of the pod, and / or the time of day determines when to dispense the contents of the pod.

[0099] If the idle time has expired, the machine 100 automatically powers down (step 272). It may also be powered down by a user by pressing the power button (286). Upon powering down, the processor opens the bypass valve 190 to equalize pressure across the valve (step 288). The machine 100 waits 10 seconds (step 290) and then shuts down the compressor 186 and the fan (step 292). The machine then shuts down.

[0100] 12 is a circuit diagram of a refrigeration system 310 that includes an evaporator 108 and an expansion subsystem 312. Refrigeration system 310 is substantially similar to refrigeration system 109. However, refrigeration system 310 includes an expansion subsystem 312 rather than the expansion valve 184 shown in refrigeration system 109. Refrigeration system 310 does not include the first and second bypass lines 188 and 190 that are part of refrigeration system 109. However, some systems include the first and second bypass lines along with the expansion subsystem 312.

[0101] The expansion subsystem 312 includes a number of valves that control the expansion of the refrigerant fluid. These valves include a first fixed orifice valve 314, a second fixed orifice valve 316, and a control valve 318. The control valve 318 is upstream of the second fixed orifice valve 316. The control valve 318 and the second fixed orifice valve 316 are connected in parallel with the first fixed orifice valve 314. The expansion device has two modes to control the temperature of the refrigerant entering the evaporator 108. In the first mode, the control valve 318 is open and allows the refrigerant to flow to the second fixed orifice valve 316. In the first mode, the refrigerant flows through both the first fixed orifice valve 314 and the second fixed orifice valve 316. In the second mode, the control valve 318 is closed and the refrigerant does not flow through the second fixed orifice valve 316. All of the refrigerant flows through the first fixed orifice valve 314 .

[0102] As discussed with reference to FIG. 4, the expansion valve 184 or expansion subsystem 312 accepts high pressure refrigerant and expels low pressure refrigerant. This pressure drop cools the refrigerant. A larger change in pressure (ΔP) results in a larger change in temperature (ΔT). In the second mode (i.e., the control valve 318 is closed), the pressure drop through the expansion subsystem 312 is higher than in the first mode, resulting in a lower evaporator pressure and an associated lower evaporator temperature. The effect on heat transfer of the increased temperature difference between the refrigerant and the contents of the pods in the evaporator 108 is offset to some extent by the fact that this lower pressure refrigerant is less dense. Because the compressor moves a fixed volume of refrigerant in each compression cycle, the mass flow rate per cycle is reduced, lowering heat transfer. In the second mode of operation, there is a large temperature difference between the pods and the evaporator, requiring a large heat transfer and increasing the amount of mass flow required.

[0103] During initial operation, the refrigeration system 310 is in a first mode. The control valve 318 is open and refrigerant flows through both the first fixed orifice valve 314 and the second fixed orifice valve 316. This causes the evaporator to operate at a temperature of approximately -20°C to -10°C. At this temperature, the refrigeration system can provide greater cooling capacity than at lower temperatures by utilizing the higher density refrigerant passing through the evaporator.

[0104] The pod 150 is inserted into the evaporator 108 at approximately room temperature (for example, 22°C). The initial temperature difference between the evaporator 108 and the pod 150 is high. As a result, heat is transferred quickly from the pod 150 to the evaporator 108. As the pod 150 cools, the temperature difference between the pod 150 and the evaporator 108 decreases, and the transfer of heat from the pod 150 to the evaporator 108 also slows. At this point, the system 310 enters the second mode and closes the control valve 318. Refrigerant flows only through the first fixed orifice valve 314, and the ΔP between the refrigerant entering the first fixed orifice valve 314 and the refrigerant exiting the first fixed orifice valve 314 increases. ΔT also increases, and as a result, the evaporator 108 becomes colder by approximately -15°C to -30°C. This reduces the cooling capacity of the system, but increases the temperature difference between the pod and nest, allowing for quicker final freezing of the ice cream.In the second mode, which operates when the temperature difference between the pod and the evaporator is reduced enough to affect heat transfer, the lower temperature refrigerant increases the total amount of heat transfer, even though there is less mass flowing through the system.

[0105] In some embodiments, the temperature of the evaporator in the first mode is above freezing. This configuration can pre-cool the evaporator before use and defrost the evaporator after use.

[0106] The configuration of refrigeration system 310 can increase temperature control, reduce freezing times, and reduce compressor power requirements, which allows for a reduction in compressor size.

[0107] In some refrigeration systems, the expansion subsystem includes more than two valves. Multi-valve subsystems have more than two modes, allowing for even greater temperature control.

[0108] In some refrigeration systems, other types of valves are used, such as, for example, thermostatic expansion valves and electronic expansion valves. Both thermostatic and electronic expansion valves can change orifice size based on various load and operating conditions. For example, a thermostatic expansion valve senses the temperature of the refrigerant at the evaporator outlet and adjusts the flow through the thermostatic expansion valve to maintain a given or desired operating condition. The electronic expansion valve is electrically operated to change the orifice size based on the evaporator outlet temperature and an electronic signal from the control unit 371.

[0109] 13 is a schematic diagram of a refrigeration system 320 that includes a refrigerant line 322 that pre-chills a water tank 324 before entering the evaporator 108. Refrigeration system 320 is substantially similar to refrigeration system 109. However, refrigeration system 320 includes a pre-chilling line 322 and eliminates the first and second bypass lines 188 and 190 that are part of refrigeration system 109. Some systems include a first bypass line, a second bypass line, and a pre-chilling line.

[0110] The refrigeration system 320 used in the machine includes a water reservoir 324. Machines with a water reservoir inject fluid into the pod during mixing, for example to dissolve dry ingredients or dilute the pod's contents. Chilled water freezes more quickly than hot or room temperature water.

[0111] In use, valve 326 operates to route refrigerant through pre-cooling such that refrigerant exiting expansion valve 184 is routed through pre-cooling line 322. Cold, low pressure refrigerant flows through pre-cooling line 322 which is located partially or completely within water reservoir 324. When water reservoir 324 is filled with water, pre-cooling line 322 is partially or completely submerged. The refrigerant cools the water in water reservoir 324 and exits pre-cooling line 322. The refrigerant then enters evaporator 108 to cool evaporator 108.

[0112] 14 is a circuit diagram of a refrigeration system 328 that includes a thermal mass 330 disposed between the compressor 186 and the condenser 180. Refrigeration system 328 is substantially similar to refrigeration system 109. However, refrigeration system 328 includes a thermal mass 330. Refrigeration system 328 does not include the first bypass line 188 and the second bypass line 190 that are part of refrigeration system 109. Some systems include a first bypass line, a second bypass line, and a thermal mass 330.

[0113] The thermal mass may be, for example, a mixture of ethylene glycol and water, salt water, paraffin wax (an alkane), or pure water. In some machines, the thermal mass 330 is disposed between the condenser 180 and the heat exchanger 182.

[0114] The thermal mass 330 stores and then releases thermal energy. When placed between the compressor 186 and the condenser 180, the thermal mass 330 stores the heat released from the refrigerant. At this point in the cycle, the refrigerant is a high-pressure vapor. The condenser 180 releases heat from the high-pressure vapor isothermally to create a high-pressure liquid. Using the thermal mass 330 to pre-cool the vapor refrigerant reduces the load on the compressor 186. When the machine 100 is turned off, the thermal mass 330 releases heat to the surrounding environment and reaches equilibrium at the ambient temperature.

[0115] Some systems include both a second bypass line and a thermal mass that diverts refrigerant from the thermal mass and idles the refrigeration system while the thermal mass dumps heat from the previous cycle into the surrounding environment.

[0116] 15 is a circuit diagram of a refrigeration system 332 including a pressure vessel 334, a first control valve 336, and a second control valve 338. The pressure vessel 334 can act as a pressure accumulator to allow for quick start-up of the system and reduce the time required to cool (e.g., to frozen) the contents of the pod in the evaporator 108. The refrigeration system 332 is substantially similar to the refrigeration system 109. However, the refrigeration system 332 includes a pressure vessel 334, a first control valve 336, and a second control valve 338. The refrigeration system 332 further does not include the first bypass line 188 and the second bypass line 190 that are part of the refrigeration system 109. Some systems include a first bypass line, a second bypass line, the pressure vessel 334, the first control valve 336, and the second control valve 338.

[0117] A first control valve 336 is disposed between the compressor 186 and the condenser 180. A second control valve 338 is disposed between the heat exchanger 182 and the expansion valve 184. A pressure vessel 334 is disposed between the condenser 180 and the heat exchanger 182. Refrigerant leaves the compressor 186 at high pressure and maintains that high pressure until the liquid refrigerant is released by the expansion valve 184. The system 332 controls the position of the valves 336, 338 (e.g., open or closed) based on the desired outcome.

[0118] During normal operation of system 332 (e.g., when cooling pods), both first control valve 336 and second control valve 338 are open. Prior to idling, second control valve 338 closes and first control valve 336 remains open. Compressor 186 continues to run for a short period of time, e.g., 1-5 seconds, before first control valve 336 closes. After first control valve 336 closes, the compressor stops.

[0119] When the system 332 is turned on again (e.g., to make a serving of chilled food or drink), the compressor 186 is restarted, the first control valve 336 is opened, and the second control valve 338 is opened. With high pressure fluid already present in the pressure vessel 334, high pressure refrigerant flows through the expansion valve 184, and the pressure drop cools the refrigerant. This approach reduces the time required to cool the contents of the pod compared to a refrigeration system where the system pressure can return to ambient conditions during shutdown. When the system is at ambient conditions, there is no pressure drop across the expansion valve initially when the system is restarted. This approach has been demonstrated to reduce the time required to cool the contents of an 8 ounce pod from room temperature to frozen to less than 90 seconds. The refrigeration system 332 is capable of quickly or instantly cooling the refrigerant when the system 332 is started or started up, e.g., prior to the insertion of the pod 150.

[0120] 16 is a circuit diagram of a refrigeration system 340 that includes a thermoelectric module 342. Refrigeration system 340 is substantially similar to refrigeration system 109, but does not include first bypass line 188 and second bypass line 190 that are part of refrigeration system 109. Some systems include a first bypass line, a second bypass line, and a thermoelectric module 342.

[0121] The thermoelectric module 342 is a cooling element disposed between the condenser 180 and the heat exchanger 182. The thermoelectric module 342 cools the refrigerant exiting the condenser 180 before transferring heat to the refrigerant vapor exiting the evaporator 108 and entering the heat exchanger 182. Cooling the liquid refrigerant before it expands increases the cooling capacity of the system 340 and reduces the required compressor power. The reduction in required compressor power reduces the size of the compressor needed.

[0122] 17 is a circuit diagram of a refrigeration system 344 that includes a thermal battery 346, a first battery bypass valve 348, and a second battery bypass valve 350. Refrigeration system 344 is substantially similar to refrigeration system 109, but does not include the first bypass line 188 that is part of refrigeration system 109. Some systems with a thermal battery 346 and associated valves also include a first bypass line.

[0123] The thermal battery 346 has a first portion 352 disposed between the heat exchanger 182 and the expansion valve 184. The first battery bypass valve 348 is disposed in a first branch line 354 that bypasses the first portion 352 of the thermal battery 346. When the first battery bypass valve 348 is open, most or all of the refrigerant flows through the first branch line 354. The thermal battery 346 has a high pressure drop. Because the branch line 354 has a relatively low pressure drop relative to the thermal battery 346, the refrigerant flows primarily through the branch line 354. When the first battery bypass valve 348 is closed, the refrigerant flows through the first portion 352 of the thermal battery 346.

[0124] The thermal battery 346 has a second portion 356, which is disposed between the evaporator 108 and the heat exchanger 182 and is thermally connected to the first portion 352. The second battery bypass valve 350 is disposed in a second branch line 358 that bypasses the second portion 356 of the thermal battery 346. When the second battery bypass valve 350 is open, most or all of the refrigerant flows through the second branch line 358. The thermal battery 346 has a high pressure drop. Because the branch line 358 has a relatively low pressure drop relative to the thermal battery 346, the refrigerant flows primarily through the branch line 358. When the second battery bypass valve 350 is closed, the refrigerant flows through the second portion 356 of the thermal battery 346.

[0125] The thermal battery 346 includes a thermal material that retains heat. The thermal battery 346 includes a reservoir 360 with a phase change material (e.g., paraffin) and accepts or releases heat depending on the positions of a first cell bypass valve 348 and a second cell bypass valve 350. The thermal battery 346 is described as using paraffin as an example of a phase change material. Some thermal batteries include other materials that retain or consume heat, such as a mixture of ethylene glycol and water, salt water, or pure water.

[0126] The thermal battery 346 dumps heat from its second portion 356 into the refrigerant when the first battery bypass valve 348 is open and the second battery bypass valve 350 is closed. If the paraffin is warm or melted, the cold refrigerant cools and solidifies the paraffin in the reservoir 360. By heating the low pressure refrigerant, the thermal battery reduces the possibility of liquid refrigerant flowing into the compressor.

[0127] When the first cell bypass valve 348 is closed and the second cell bypass valve 350 is open, the thermal cell 346 receives heat from the refrigerant at the first portion 352. If the wax is solidified, the hot liquid refrigerant heats and melts the wax in the wax reservoir 360. If the wax is liquid, the hot refrigerant continues to heat the liquid wax in the wax reservoir 360.

[0128] During the cooling cycle in operation of the system 344, both the first battery bypass valve 348 and the second battery bypass valve 350 are open, allowing little or no refrigerant to flow to and interact with the thermal battery 346. At the end of the cooling cycle, the second battery bypass valve 350 closes, allowing the cold low pressure refrigerant to cool the reservoir 360. When the next cycle begins in which the battery has cooled, the second battery bypass valve 350 opens and the first battery bypass valve 348 closes. The first portion 352 of the thermal battery 346 then pre-cools the hot liquid refrigerant that exited the condenser 180 and passed through the heat exchanger 182.

[0129] This configuration reduces the heat load on the compressor, preventing it from flooding at the end of the cycle and allowing the compressor to be powered down. Some waxes, for example dodecane wax or tridecane wax, may have melting points in the range of 5°C to -10°C.

[0130] Fig. 18A is a plan view of the evaporator cover 127, and Fig. 18B is a plan view of the body of the evaporator 108. The body of the evaporator 108 defines a channel 366 through which refrigerant flows to cool the evaporator 108. As shown in Fig. 18B, the channel 366 is open at an edge 367 of the evaporator 108. The channel 366 is also open at the opposite end of the evaporator 108, which has a similarly configured edge.

[0131] The cover 127 includes a number of recesses 174 that align with four adjacent channels 366 of the evaporator 108 when the cover 127 is attached to the body of the evaporator 108. Some covers include recesses that align with other numbers of adjacent channels. The recesses 174 act as a manifold that fluidly connects the adjacent channels 366. The covers 127 at opposite ends of the evaporator body are offset such that the two covers 127 and the body of the evaporator 108 together define a serpentine flow path through the evaporator 108.

[0132] The cover 127 has an inlet 370 and an outlet 372 that fluidly connect the evaporator 108 and the refrigeration system 109. Refrigerant flows through the inlet 370, through channels defined by recesses in the body of the evaporator 108 and the cover 127, and exits the evaporator 108 through the outlet 372. The refrigerant enters the inlet 370 as a cold fluid at a first temperature. As the refrigerant flows through the flow passages 368, it warms and evaporates due to heat from the pods 150 received by the evaporator 108. The pods 150 are frozen by this heat transfer. To maintain a constant flow rate, the diameter of the inlet 370 is approximately 0.25 inches and the diameter of the outlet 372 is approximately 0.31 inches.

[0133] The living hinge 132 defines a connecting channel 373 that fluidly connects the channel in the first portion 128 of the evaporator 108 with the channel 366 in the second portion 130 of the evaporator 108. The connecting channel 373 is defined inside the evaporator 108 near the edge 367 of the evaporator 108. In some evaporators, the edge of the evaporator defines a groove and the lid defines a corresponding groove such that a connecting channel is created between the groove in the lid and the groove in the evaporator when the lid and evaporator are engaged. Some connecting channels are defined inside the cover 127. This configuration defines a continuous flow path 368 from the inlet 370 to the outlet 372 with the channel 366 extending parallel to the axis 369 to provide fluid flow parallel to the axis 369.

[0134] In some evaporators, the channels 366 run from edge 367 through the interior of the evaporator and connect at opposite ends to form a "U" shape. When assembled, the cover 127 is placed on edge 367 of the evaporator 108. The channels 366 are a series of unconnected "U" shaped units. In each unit, a first channel carries refrigerant in a first direction and a second channel carries fluid in a second direction opposite the first direction.

[0135] The channels 366 extend parallel to the axis 369 of the evaporator. In some evaporators, the channels do not extend parallel to the axis, but to each other. In some evaporators, the channels do not extend parallel to each other or to the axis.

[0136] 19A and 19B are perspective views of an evaporator 380 without and with its cover 127, respectively. The evaporator 380 in FIGS. 19A and 19B operates similarly to the evaporator 108 described in FIGS. 18A-18E. However, the evaporator 380 includes a recess 382 that fluidly connects the second channel 366b of a unit 371 with the first channel 366a of a different unit 371. The cover 384 is substantially similar to the cover 127. However, the cover 384 is flat rather than recessed at the surface that abuts the edge 367, and includes multiple inlets and outlets rather than one inlet and one outlet. The cover 384 includes a first inlet 388 in the first portion 128, a first outlet 390 in the first portion 128, a second inlet 392 in the second portion 130, and a second outlet 394 in the second portion. The first inlet 388 and first outlet 390 are fluidly connected to create a first flow path 396 in the first section 128. The second inlet 392 and second outlet 394 are fluidly connected to create a second flow path 398 in the second section 130. This configuration creates two flow paths 396, 398 that allow refrigerant to flow in parallel and do not use a hinge connector. To maintain flow velocity, the diameters of the flow paths 396, 398 are reduced so that the separated flow paths have a similar flow area as the original flow paths.

[0137] When the cover 384 engages the evaporator 380 , the recess 382 is closed and the evaporator 380 and cover 384 create flow passages 396 , 398 .

[0138] In the evaporators described above, the units 371 have a "1 up / 1 down" configuration. In some evaporators, the units define a "2 up / 2 down" or "3 up / 3 down" configuration. This allows the proper flow rate to be maintained while minimizing the pressure drop inside the evaporator. Different compressors and different cooling tasks require different flow path arrangements. The number of parallel flow paths can be increased for larger compressor and cooling loads and decreased for lesser demands.

[0139] Figures 20A-20D are schematic diagrams of the flow paths created by the channels of the evaporator and the recesses in its cover 127. Figures 20A and 20B are drawings of the channels defined within the evaporator. Figures 20C and 20D are perspective views of the evaporator and its cover 127.

[0140] FIG. 20A is a flow path 402 in which the number of channels 400 increases as the refrigerant evaporates. The refrigerant enters at the inlet and flows through one or more single channels 400a. As the refrigerant evaporates, it expands in volume and starts to move faster. The vapor can expand in specific volume by about 50-70 times. To slow down the mixed-phase refrigerant inside the evaporator 108, the flow path 402 branches into two parallel channels 400b that connect at the recess 374 and inside the evaporator 108 at the branch point 306. As more refrigerant evaporates, the flow path 402 again branches into three parallel channels 400c that connect at the recess 374 and inside the evaporator 108 at the branch point 306. Some evaporators maintain a "2 up / 2 down" configuration in multiple units. Some evaporators maintain a "3 up / 3 down" configuration in multiple units. In some evaporators, the flow paths are increased to a "4 up / 4 down" or "5 up / 5 down" configuration. Increasing the number of channels throughout the evaporator increases performance early in the evaporation process while limiting the high velocities / pressure drops toward the evaporator exit.

[0141] 20B is a schematic diagram of a flow path 402 with a scaling recess 408 in the cover 127 that acts as a manifold. The scaling recess 408 has a smoothly increasing and decreasing cross-sectional area that helps maintain the flow rate of the refrigerant through the manifold. The scaling recess in the cover also helps maintain the flow rate and reduces pressure drop and flow separation of the liquid and gas refrigerant due to low flow rate regions.

[0142] 20C shows a first manifold at the bottom of the evaporator 108 and a flow path 420 including multiple branches 424 extending from the first manifold 422 towards the cover 127. The first manifold 422 connects to the inlet 370. The branches 424 fluidly connect to a second manifold 426 at the top of the evaporator 108. The second manifold 426 fluidly connects to the outlet 372.

[0143] The refrigerant flows from the inlet through the first manifold 422 up the branch 424 and through the second manifold 426 to the outlet 372. Vapor is less dense than liquid and tends to rise to the top. This preferential flow direction can produce unpredictable flow and performance when the flow direction is downward. This configuration can increase the thermal performance of the evaporator 108 by forcing the refrigerant to flow in the same direction as the buoyancy forces that exist when the refrigerant is in vapor form.

[0144] FIG. 20D shows a flow path 430 that circles the evaporator 108. The flow path 430 is a spiral that follows the outer diameter of the evaporator 108. This configuration reduces pressure drop by increasing the area and reducing or eliminating sharp turns in the flow path 430. In some evaporators, multiple hinge connectors are used to connect a first portion of the evaporator to a second portion of the evaporator as the flow path extends throughout the first portion and the second portion. Some flow paths define a serpentine path in the first portion and a serpentine path in the second portion connected by a hinged "transition path."

[0145] 21A-21C are drawings of a pod 150 and an evaporator 438 with a closing mechanism 440. FIG. 21A is a perspective view of the evaporator 438 and the pod 150. FIG. 21B is a cross-sectional view of the pod 150 and the evaporator 438. FIG. 21C is a plan view of the pod 150 and the evaporator 438.

[0146] The closing mechanism 440 includes a biasing element (e.g., a spring) that connects the first portion 128 of the evaporator 438 and the second portion 130 of the evaporator 438. The closing mechanism 440 also includes a perimeter cable 441 that extends around the outer diameter of the evaporator. The cable is tightened near the pod and loosened to open the evaporator.

[0147] The biasing elements in the evaporator 438 include a first spring 442 and a second spring 444 that bias the first and second parts 128, 130 away from each other. The living hinge 132 facilitates the movement of the first and second parts 128, 130 such that the rotation of the first and second parts 128, 130 around the hinge 132 is due to the biasing forces of the springs 442, 444. In this configuration, the evaporator 438 is in an open position and a small gap 446 is created between the first and second parts 128, 130. When the cover 127 is in an open position, the evaporator 438 is also in an open position. In some machines, the position of the evaporator is independent of the position of the lid. In the open position, a small gap exists between the evaporator 438 and the pod 150.

[0148] The evaporator 438 has a closed position in which the gap between the evaporator 438 and the pod 150 is eliminated to promote heat transfer. In some evaporators, the gap is effortlessly reduced. In the closed position, the gap 446 is also eliminated. In some evaporators, the gap is reduced rather than eliminated. To move from the open position to the closed position, the closing mechanism 440 applies a force in the direction of the arrow 448 to overcome the biasing force of the first spring 442 and the second spring 444.

[0149] The closing mechanism generates a force in the range of 10-1500 lbs. It is preferable that the internal pressure of the pod 150 is equal to or greater than the force generated by the closing mechanism 440 to prevent the pod 150 from collapsing.

[0150] The closure mechanism 440 may be, for example, an electromechanical actuator, a pulley system, a lever, a protrusion in the lid, a ball screw, a solenoid, or a mechanical latch.

[0151] 22A and 22B are side and front views, respectively, of an evaporator 108 with a closure mechanism 440 that includes two bolts 450 inside a spring 456. The bolts 450 bias a rod 466 away from a flange 464. Optionally, a cable 468 is received in a hole defined in the rod 466 and extends around the evaporator 108.

[0152] 23A shows an evaporator 500 that can be produced primarily by extrusion. The evaporator 500 has a body 510 with two end caps 512. The body 510 and the end caps are produced separately and then assembled.

[0153] Figures 23B and 23C illustrate the manufacture of the body 510. The evaporator body 510 is produced by low cost extrusion. The body is extruded with channels 514 defined in the body 510 (see Figure 23B). Each end of the body 510 is machined to provide a step 516 that mates with the end cap (see Figure 23C). A wall 518 extends beyond the step 516.

[0154] 23D and 23E are perspective views of the end cap 512. The end cap 512 can be forged or machined. The end cap 512 provides the inlet and outlet and closure features for the evaporator 500. The end cap 512 has a side wall 520 and an end wall 522.

[0155] The end cap 512 has a number of ridges 524 extending outwardly from the side wall 520. The ridges 524 can be used to mount and manipulate the end cap 512 to the evaporator 500 after assembly of the body 510. A port 526 extends through the side wall 520. The port 526 in the end cap 512 at one end of the evaporator 500 is used as an inlet and the port 526 in the end cap 512 at the other end of the evaporator 500 is used as an outlet.

[0156] 23F illustrates the assembly of the evaporator 500. An end cap 512 is mounted to a step 516 at one end of the body 510. After mounting, the joint between the evaporator body 510 and the end cap 512 is easily accessible. This configuration facilitates the use of laser welding, vacuum brazing, friction stir welding, or TIG welding to attach the end cap 512 to the evaporator body 510.

[0157] 23G and 23H illustrate the relationship of the body 510 and end cap 512 after assembly. When assembled with the body 510, the side and end walls 520 and 522 of the end cap and the wall 518 of the body 510 define a chamber that acts as a manifold connecting the channels defined in the body 510 of the vaporizer 500. The end cap 512 is shown as having a "hollow" configuration with all passages connected in parallel for upward evaporation, but can also accommodate a multi-passage design with multiple 180 degree turns.

[0158] FIG. 24 illustrates an evaporator 500 configuration incorporating an orifice plate 530. The orifice plate 530 is disposed between the body 510 and the end cap 512. The orifice plate 530 defines a number of orifices 532 that align with the channels 514 in the body 510 after assembly. The orifice plate can be used to evenly distribute the flow to the channels 514 by accumulating the refrigerant in front of the orifice plate 530 and injecting the liquid and gas mixture evenly into the channels 524. In some cases, the orifices are of equal size. In some cases, the orifices can be of different sizes if unequal distribution of flow between the passages 514 is likely.

[0159] FIG. 25 is a perspective view of an embodiment of the evaporator 380 described with reference to FIGS. 19A and 19B with an inner surface 470 made of a different material than the rest of the evaporator 380. The inner surface 470 is made primarily or entirely of copper. Copper has a higher thermal conductivity (approximately 391 W / mK) than aluminum, which has a thermal conductivity of 180 W / mK. High thermal conductivity transfers heat quickly and efficiently from the pod to the refrigerant. Materials with low thermal conductivity transfer heat slower and less efficiently. The ability of a component to act as a heat sink is a function of both its thermal conductivity and mass. Table 2 lists the thermal conductivities and densities of various materials. [Table 2]

[0160] Figures 26A-C are schematic diagrams of claddings. These claddings can be used for evaporators containing both aluminum and copper. Figure 26A shows an overlay cladding 490. Figure 26B shows an inlay cladding 492. Figure 26C shows an edge cladding 495. Cladding techniques such as those shown in Figures 26A-C are applied to the interior surfaces of the evaporator. Due to the high thermal conductivity of copper, various cladding techniques can increase heat transfer and dissipate the heat.

[0161] 27 is an exemplary drawing of a material 480 that includes microchannels 482. When material 480 is used to create an evaporator, for example, refrigerant flows through the microchannels 482. Material 480 can be curved to create an evaporator that cools the pod 150. Material 480 is permanently deformed into a tubular shape to create a round evaporator. Such an evaporator has a large surface area that increases evaporator performance while maintaining low cost.

[0162] 28A-28C show a rotary compressor 550 that may be used in some refrigeration systems in place of the reciprocating compressor 186 described above. The compressor 550 includes a housing 552 having an interior wall 553 that defines an interior cavity 554. An inlet 556 and an outlet 558 fluidly connect the interior cavity 554 of the compressor 550 with other components of the refrigeration system. A pressure valve 559 releases the fluid when the fluid reaches a predetermined pressure. A roller 560 with a circular cross section rotates and axially constrains an extension rod 562 that extends through the bottom of the housing 552. Some rollers have an elliptical or gear-shaped cross section. The rod 562 is mounted off-center of the circular cross section of the roller 560. The rod 562 and roller 560 rotate relative to the housing 557 using a motor (not shown). The roller 560 is arranged within the cavity 554 such that an edge 564 of the roller 560 extends to the inner wall 553 of the housing. In this configuration, the roller 560 creates a seal with the housing 557. The edge 564 of the roller 560 maintains contact with the wall 553 as the rod 562 and roller 560 rotate within the interior cavity 554. The housing 557 includes a notched area 566 for containing a compression spring 568. The spring 568 contacts the roller 560. A rubber member 570 surrounds a portion of the spring 568, creating a seal that extends from the wall 553 to the roller 560. The spring 568 expands and contracts as the roller 560 rotates within the interior cavity 554 to maintain the seal.

[0163] In FIG. 28A, the compressor 550 is in a first state. In FIG. 28B, the rotary compressor 550 is in a second state, and in FIG. 28C, the rotary compressor 550 is in a third state. The rotary compressor 550 moves from the first state to the second state, from the second state to the third state, and from the third state to the first state. In the first state, the roller 560 receives low pressure cooling steam from the evaporator 108 via the inlet 556. The seal between the contact edge 564 and the wall 553 and the seal between the member 570 and the roller 560 define the intake chamber 572 and the pressurized chamber 574. In some rotary compressors, additional seals are created to increase the number of chambers. The roller 560 rotates to compress and pressurize the steam in the pressurized chamber 574, and takes in the steam from the inlet 556 and draws it into the chamber 572. In the second state shown in FIG. 28B, the roller 560 continues to rotate counterclockwise until the pressure valve 559 releases the high pressure steam exiting the compressor 550, increasing the pressure of the steam in the pressurized chamber 574. The intake chamber continues to receive low pressure steam from the inlet 556. The compression spring 568 extends into the internal cavity 554 as the roller 560 rotates, maintaining the connection between the member 570 and the roller 560. In the third state shown in FIG. 28C, the high pressure steam is expelled from the pressurized chamber 574 and the spring 568 is compressed into the notch area 566. In this state, only one seal is made between the contact edge 564 and the member 570. For a short period during the cycle, the number of chambers is reduced by one. In this state, the intake chamber 572 becomes the pressurized chamber 574 in the compressor 550. An intake chamber 572 is again created when contact edge 564 passes member 570 such that two seals are made, one between member 570 and roller 560 and the other between contact edge 564 and wall 553 .

[0164] Rotary compressors perform the same thermal duty as reciprocating compressors at a much lighter weight and smaller size. Rotary compressors weigh from about 10 to about 18 lbs. Rotary compressors have a refrigerant displacement of from about 4 cc to about 8 cc. Rotary compressors have a performance-to-weight ratio of from about 0.3 cc / lb to about 0.5 cc / lb.

[0165] A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications can be made without departing from the spirit and intent of the invention of the present disclosure. Accordingly, other embodiments are within the scope of the following claims.

Claims

1. 1. A machine for producing a cooled food or beverage from ingredients in a pod containing the ingredients, the machine comprising: Housing and a refrigeration system having a working fluid loop of two-phase refrigerant running from an evaporator to a compressor, to a condenser, to an expansion device, and back to the evaporator, the evaporator defining a receptacle sized to receive the pod; a motor operable to move a mixing paddle of the pod within the receptacle; Equipped with The evaporator comprises: a body defining a plurality of longitudinally extending channels spaced such that the channels extend around a circumference of the evaporator between an inlet and an outlet; a first cover attached to one end of the body; a second cover attached to another end of the body; and Equipped with the first cover and the second cover act as a manifold connecting the channels, and the compressor provides a mass velocity of fluid of 60,000 to 180,000 lb / hr; The motor is operable to mix the ingredients within the pod during cooling to produce the cooled food or beverage within two minutes.

2. 10. The machine of claim 1, wherein the pressure drop through the refrigeration system is less than 2 psi.

3. 10. The machine of claim 1, wherein the evaporator pod-to-evaporator heat transfer area is between 15 and 50 square inches.

4. 10. The machine of claim 1, wherein the evaporator refrigerant wetted area is between 35 and 200 square inches.

5. 10. The machine of claim 1, wherein the evaporator is made of a material having a thermal conductivity of at least 160 W / mK, and the evaporator has a mass of between 0.100 and 1.50 pounds.

6. 6. The machine of claim 5, wherein the pressure drop through the refrigeration system is less than 2 psi.

7. 2. The machine of claim 1, wherein the evaporator is a cylindrical evaporator that clamps around the pod during use.

8. 8. The machine of claim 7, wherein the evaporator has an inner wall of copper that is adjacent to the pod in use.

9. 10. The machine of claim 8, further comprising R-290 propane as a refrigerant.

10. 1. A machine for producing a cooled food or beverage from ingredients in a pod containing the ingredients, the machine comprising: Housing and a refrigeration system having a two-phase refrigerant working fluid loop running from an evaporator to a compressor, to a condenser, to an expansion valve or capillary tube, and back to the evaporator; Equipped with the evaporator defines a receptacle sized to receive the pod, the evaporator having a heat transfer area of ​​between 15 and 50 square inches, the evaporator comprising: a body defining a plurality of longitudinally extending channels spaced such that the channels extend around a circumference of the evaporator between an inlet and an outlet; a first cover attached to one end of the body; a second cover attached to another end of the body; and Equipped with The machine, wherein the first cover and the second cover act as a manifold connecting the channels, and the mass of the body, the first cover, and the second cover is between 0.100 and 1.50 pounds.

11. 11. The machine of claim 10, further comprising a motor operable to move a mixing paddle of the pod within the receptacle to mix the ingredients within the pod during operation of the refrigeration system.

12. 11. The machine of claim 10, wherein the pressure drop through the refrigeration system is less than 2 psi.

13. 11. The machine of claim 10, wherein the evaporator refrigerant wetted area is between 35 and 200 square inches.

14. 11. The machine of claim 10, wherein the evaporator is a cylindrical evaporator that clamps around the pod during use.

15. 15. The machine of claim 14, wherein the evaporator has an inner wall of copper that is adjacent to the pod in use.

16. 16. The machine of claim 15, further comprising R-290 propane as a refrigerant.

17. 17. The machine of claim 16, wherein the evaporator has cooling channels therein that allow a mass rate of fluid of between 60,000 and 180,000 lb / hr.

18. 18. The machine of claim 17, wherein the compressor is a rotary compressor.

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