Three-dimensionally shaped food made by combining block-shaped ingredients and its manufacturing method

Abstract

To provide a food product having a shaped three-dimensional structure with a desired appearance, texture, nutrition, etc., and a method for producing the same. This food has a three-dimensional structure formed by combining block-shaped ingredients, the block-shaped ingredients having a roughly cubic shape with a side length of 1 mm to 10 mm, and the three-dimensional structure is formed by combining and arranging a plurality of block-shaped ingredients in a desired positional relationship with each other and joining them together.

Description

[Technical Field]

[0001] The present invention relates to a three-dimensionally shaped food product that is constructed by combining block-shaped ingredients and can be designed into a desired shape, etc., and a method for manufacturing the same. In particular, the present invention relates to a food product having a shaped three-dimensional structure that has a desired appearance, texture, nutrition, etc., and that can be obtained by preparing block-shaped ingredients having predetermined properties in advance and combining them according to a desired design and method, and a method for manufacturing the same. [Background technology]

[0002] Manufacturing using 3D printers, which can create three-dimensional objects (products) based on three-dimensional data, has become popular since around 2013, and food 3D printers that can create products by directly layering food have also been developed. There are two main types of food 3D printers: one type fills a syringe with food paste and extrudes it to form layers, and the other type solidifies powdered ingredients such as sugar with water or oil and then layers them.

[0003] For example, WO 2017 / 006330 discloses a method and apparatus for three-dimensionally printing food products, which comprises premixing a raw material composition containing various ingredients, extruding the premixed raw materials from a nozzle that moves relative to a deposition tray, and curing the deposited raw materials with UV radiation or heating with IR radiation.

[0004] Furthermore, WO 2016 / 177628 discloses a food processing method and apparatus in which powdered food ingredients are transported from multiple containers to corresponding dispensers, the dispensers are moved in X, Y, and Z directions while the food ingredients are deposited to form food layers, and after repeating this process, the deposited food is selectively heated.

[0005] With these conventional methods and devices, the materials that can be used as ingredients for food production are limited to those that can be made into an extrudable paste or a dispensable powder. For this reason, they cannot be used with ingredients that lose their food value when made into a paste or powder. For these reasons, although concept models have been announced for either of the two types of food 3D printers mentioned above, there have yet to be any examples of them being put into practical use or commercialized.

[0006] Furthermore, development is also underway on technology to create food using inkjet-type 3D printers. For example, WO 2015 / 106059 discloses a method for producing a three-dimensional food product, in which a food material containing predetermined amounts of polysaccharides and monosaccharides is deposited in successive layers according to digital data describing the three-dimensional food product, and an edible binder is applied to specific areas of the deposited layers. However, this method requires the use of special edible sugar-based ingredients, and the foods that can be shaped by this method are limited to sugar confectionery. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] International Publication No. 2017 / 006330 [Patent Document 2] International Publication No. 2016 / 177628 [Patent Document 3] International Publication No. 2015 / 106059 Summary of the Invention [Problem to be solved by the invention]

[0008] The present invention aims to provide a food product having a three-dimensional structure obtained by three-dimensional molding, which does not require the use of paste-like or powdered food ingredients or food materials with specific components, something that could not be obtained with conventional technology, and a method for producing the same. Another object of the present invention is to provide a three-dimensionally shaped food product and a method for manufacturing the same, which can be individually adjusted to have a hardness that makes it easy to swallow and to provide the necessary nutrients, for example as a nursing care food product. Another object of the present invention is to provide a three-dimensionally shaped food product and a method for manufacturing the same, which can be used as space food, for example, to enable a variety of meals to be combined according to individual preferences even within a limited space. [Means for solving the problem]

[0009] The inventors have discovered that the above problem can be solved by preparing block-shaped food ingredients having predetermined properties in advance and combining them according to the desired design and method to create a three-dimensionally shaped food product.

[0010] That is, the present invention provides a food product having a three-dimensional structure formed by combining block-shaped ingredients, The block-shaped food material has a substantially cubic shape with a side length of 1 mm to 10 mm, A three-dimensional structure is formed by combining and arranging a plurality of the block-shaped ingredients in a desired positional relationship and joining them together. The food product is characterized in that: The block-shaped food material may be obtained by hardening a fluid material. In this case, the fluid material may be chocolate, candy, jelly, or yokan. Furthermore, the plurality of block-shaped ingredients may have a shape corresponding to the shape of a mold for hardening the fluid ingredient. The food product of the present invention may contain an edible glue for bonding the block-shaped food ingredients together. In this case, the edible glue may be selected from the group consisting of gelatin, edible glue, and gelatin. In the food product of the present invention, the desired positional relationship between the plurality of block-shaped ingredients may be determined based on 3D data created in advance.

[0011] The present invention also provides a method for producing a food product having a three-dimensional structure formed by combining block-shaped food ingredients, comprising: A step of preparing a plurality of block-shaped ingredients having a substantially cubic shape with a side length of 1 mm to 10 mm; a step of combining and arranging the plurality of block-shaped ingredients so as to have a desired positional relationship with each other; a step of joining the arranged plurality of block-shaped food materials to each other to form a food product having a three-dimensional structure; The manufacturing method is characterized by comprising: In the manufacturing method of the present invention, the plurality of block-shaped food ingredients can be prepared by hardening a fluid raw material. In this case, the fluid material may be chocolate, candy, jelly, or yokan. Furthermore, the fluid raw material can be placed in a mold having a shape corresponding to the shape of the plurality of block-shaped ingredients and allowed to harden. In the manufacturing method of the present invention, the arranged plurality of block-shaped food materials can be bonded to one another with edible glue. In this case, the edible glue may be selected from the group consisting of gelatin, edible glue, and gelatin. In the manufacturing method of the present invention, the desired positional relationship of the plurality of block-shaped ingredients can be determined based on 3D data created in advance. [Effects of the Invention]

[0012] According to the present invention, any food ingredient that can be formed into a block shape and joined (for example, glued with edible glue) can be shaped into a food product with a three-dimensional structure, and ingredients such as raw vegetables and meat that could not be handled with conventional technology can be used directly for shaping. Furthermore, when creating food with a three-dimensional structure, it is possible to design food with the desired texture and flavor by combining and arranging block-shaped ingredients so that there is space inside the three-dimensional structure. Furthermore, it is possible to create foods that have never been seen before, and it is expected that this technology will be used in food-related entertainment. The food product and its manufacturing method of the present invention can be expected to be applied to space food and health food because it is possible to design the nutritional components of a food product having a three-dimensional structure composed of block-shaped ingredients by devising the block-shaped ingredients used. Furthermore, the present invention makes it possible to create food products with a three-dimensional structure, even if the ingredients are very soft, something that could not be handled with conventional technology, by molding them into blocks and joining them together, and is expected to be applicable to hospital food and nursing care food.

[0013] The present invention can also be applied to entertainment-related three-dimensional food products. For example, the present invention can provide a three-dimensional food product that looks like sushi but tastes like a sweet dessert. Because block-shaped ingredients are used in the present invention, the surface shape of the food product will be jagged, but this may be perceived as interesting and potentially increase the value of the product. Furthermore, by reducing the size of the block-shaped ingredients or preparing block-shaped ingredients in other shapes, such as spheres or polyhedrons, it is possible to change the unevenness of the food product's surface shape. Alternatively, the surface of the food product can be smoothed by processing the food product after shaping, such as by scraping the surface or applying another ingredient to the surface of the food product.

[0014] Furthermore, by using vegetables as ingredients for the block-shaped ingredients, it is possible to create uniquely designed salads that even people who don't like vegetables can enjoy. This concept can be applied to health foods, hospital meals, nursing care meals, space food, and more, as it allows for the design of balanced nutrition. In particular, in the fields of hospital and nursing care meals, there is a demand for soft and easy-to-swallow ingredients due to swallowing issues. Even if ingredients are too soft to stack using conventional technology, the present invention makes it possible to create food by pre-forming them into blocks and stacking them to form them into a shape. In this case, freezing the block-shaped ingredients allows for easy placement and joining, while softening the food when consumed, or cooking the product after shaping it to soften it. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 shows one embodiment of a block-shaped food material that can be used in the present invention, including (a) a prototype of the block-shaped food material mold, (b) the block-shaped food material mold, (c) a first block-shaped food material, (d) a second block-shaped food material, and (e) a third block-shaped food material. [Figure 2] FIG. 10 is a diagram showing image data used when arranging block-shaped food ingredients in the above-described embodiment of the present invention, and a food product shaped based on the data. [Figure 3A] In another embodiment of the present invention, this shows a top view and an oblique view of the image data of each layer used when arranging block-shaped ingredients, and a diagram (top view) showing food shaped based on the data. [Figure 3B] In another embodiment of the present invention, this shows a top view and an oblique view of the image data of each layer used when arranging block-shaped ingredients, and a diagram (top view) showing food shaped based on the data. [Figure 3C] In another embodiment of the present invention, this shows a top view and an oblique view of the image data of each layer used when arranging block-shaped ingredients, and a diagram (top view) showing food shaped based on the data. [Figure 3D]In another embodiment of the present invention, this shows a top view and an oblique view of the image data of each layer used when arranging block-shaped ingredients, and a diagram (top view) showing food shaped based on the data. [Figure 3E] In another embodiment of the present invention, this shows a top view and an oblique view of the image data of each layer used when arranging block-shaped ingredients, and a diagram (top view) showing food shaped based on the data. [Figure 3F] In another embodiment of the present invention, this shows a top view and an oblique view of the image data of each layer used when arranging block-shaped ingredients, and a diagram (top view) showing food shaped based on the data. [Figure 3G] In another embodiment of the present invention, this shows a top view and an oblique view of the image data of each layer used when arranging block-shaped ingredients, and a diagram (top view) showing food shaped based on the data. [Figure 3H] In another embodiment of the present invention, this shows a top view and an oblique view of the image data of each layer used when arranging block-shaped ingredients, and a diagram (top view) showing food shaped based on the data. [Figure 4] Regarding one embodiment of the present invention shown in Figure 3, (a) three-dimensional image data that is the basis for the image data of Figures 3A to 3H and (b) front, (c) side, and (d) back views of a food product formed by combining the ingredients arranged in Figures 3A to 3H are shown. [Figure 5] One embodiment of a block-shaped food material that can be used in the present invention includes: (a) a prototype of a block-shaped food material mold; (b) an enlargement of a convex portion of the prototype; (c) a design of the prototype; (d) an enlargement of a convex portion of the designed prototype; and (e) a silicone mold made using the prototype. [Figure 6] FIG. 1 is a perspective view of an example of a robotic arm that can be used to manufacture food products having three-dimensional structures according to the present invention. [Figure 7] FIG. 10 is a perspective view of an example of a jig for suctioning block-shaped food ingredients, which is attached to a robot arm. [Figure 8] In another embodiment of the present invention, (a) a design drawing used when arranging block-shaped ingredients, (b) a diagram (oblique view) showing a food product created based on the drawing, and (c) a cross-sectional design drawing. DETAILED DESCRIPTION OF THE INVENTION

[0016] Hereinafter, an embodiment of the present invention will be described.

[0017] <Block-shaped ingredients> The block-shaped food material used in the present invention has a roughly cubic shape with a side length of 1 mm to 10 mm. If the length of one side of the block-shaped food material is 1 mm or more, the block-shaped food material is easy to handle when arranged, and if it is 10 mm or less, the food made from the block-shaped food material will be of an easy-to-eat size. By forming the block-shaped food material into a substantially cubic shape, the degree of freedom in designing the food product to be formed is increased, and it is also easier to arrange the block-shaped food material. The block-shaped ingredients can be prepared in a variety of ways depending on the type of ingredients, such as:

[0018] (1) Block-shaped food ingredients cut into pieces Meat, seafood, processed foods such as tofu and kamaboko, vegetables, and fruits can be cut into block-shaped ingredients that can be used in the present invention using various types of cutters such as knives, vegetable cutters, and egg slicers. For example, a vegetable cutter sold under the product name "Alligator" has a cutter width of 6mm x 6mm, and cuts vegetables by pressing a stainless steel blade against a plastic body with a grid-like groove. Using this vegetable cutter, for example, by pressing the blade against vegetables that have been sliced to a thickness of 6mm, it is possible to create cubic blocks of food with sides measuring 6mm. This vegetable cutter is suitable for creating block-shaped food using vegetables in general and foods with a certain degree of hardness, such as kamaboko. An egg slicer cuts food such as boiled eggs by pressing metal wires arranged at 5mm intervals against the food. For example, the food is first sliced once to create 5mm-thick slices, then the sliced food is cut perpendicular to the slicing surface, rotated 90 degrees, and cut again to create a cubic block of food with sides measuring 5mm, such as a boiled egg. This method is suitable for relatively soft foods such as boiled eggs and kiwifruit.

[0019] (2) Block-shaped food ingredients formed using a mold The block-shaped food material usable in the present invention can be one obtained by hardening a fluid raw material. Examples of such food materials include solid foods such as chocolate and candy that melt when heated and solidify when cooled, and jelly-like foods such as jelly and yokan that are solidified with a gelling agent such as agar or gelatin. Foods formed by hardening a fluid raw material can be produced by preparing a mold having a shape corresponding to the shape of the block-shaped food material, pouring the fluid raw material into the mold, allowing it to harden, and then removing it from the mold to obtain a block-shaped food material usable in the present invention. It is also possible to prepare a block of food material, like ice or dry ice, which exists only when the food is being shaped and then disappears, forming a cavity in the food.

[0020] (3) Preliminary processing of block-shaped ingredients Edible glue can be applied to block-shaped ingredients in advance to make it easier for the ingredients to stick together. By changing the concentration of the glue applied, the hardness of the glue can be changed, allowing for variations in texture. Furthermore, ingredients that make it easier to handle when placing block-shaped food materials can be blended or applied. Furthermore, by infusing nutrients such as vitamins and sugars into block-shaped food products, it is possible to give the food functionality and make it easier to replenish nutrients. It is also possible to add ingredients that improve shelf life. For some foods, creating blocks with a porous structure like a sponge can create diet foods that have volume but are low in calories. Once the block is created, holes can be drilled using a drill-like processing tool. The powder generated during processing can be re-formed into block-shaped ingredients by solidifying it with a gelling agent, which also reduces food waste.

[0021] <Arrangement of block-shaped ingredients> (1) Creating data for placement 3D data is created in advance to determine how block-shaped ingredients should be combined and arranged to form the food product, and the desired positional relationship of the block-shaped ingredients can be determined based on the previously created 3D data. 3D data is mainly created using 3D-CAD, a software that creates three-dimensional shapes. There are many types of 3D-CAD available, ranging from freeware to expensive programs costing several million yen. 3D data created with 3D-CAD can be converted into blocks (voxels), allowing the converted data to correspond to block-shaped ingredients. For example, "Block Maker" (registered trademark) sold by Andor Co., Ltd. allows users to create 3D data by stacking blocks from the beginning, making it easy to use even for beginners. Furthermore, "Dot Art Nanika" operated by YGGDRASILL SOFT allows users to create pixel art from flat illustrations. When determining how to combine and arrange block-shaped ingredients to create food in accordance with the present invention, many software programs such as those mentioned above are relatively easily available, allowing individuals to select and use software that is easy to use. Among the currently popular game software genres, such as "Minecraft" (registered trademark), is one in which users can freely combine cubic blocks in a virtual 3D space to create objects for fun. Using 3D data created in such programs, it is conceivable to create food by combining and arranging block-shaped ingredients in accordance with the present invention, creating an amusement experience in which 3D data is expressed as food. This is one way in which users can freely create data. In line with this trend, Autodesk has released free, web-based 3D CAD software (Tinkercad). This 3D CAD can save 3D data of objects created in the software in a format that can be imported into "Minecraft" (registered trademark). Such 3D data can also be used as data when combining and arranging block-shaped ingredients in accordance with the present invention to create food. Regarding "Minecraft" (registered trademark), Microsoft acquired Mojang, the developer of the "Minecraft" (registered trademark) game software, and has begun releasing a free version of "Minecraft" (registered trademark) for educational purposes. As efforts toward 3D data are progressing in the field of education, it is conceivable that 3D data created in educational settings could be used as data for creating food by combining and arranging block-shaped ingredients in accordance with this invention.

[0022] (2) Arrangement of block-shaped ingredients Block-shaped ingredients can be arranged in order according to pre-created data. This can be done manually, but can also be done by a robot or a three-dimensional plotter. For example, in recent years, it has become possible to obtain relatively inexpensive general-purpose robotic arms such as "DOBOT." By attaching a soft hand (end effector) to the tip of such a robotic arm, it is possible to grasp block-shaped ingredients and place them in desired three-dimensional positions, automatically constructing food with a three-dimensional structure.

[0023] <Joining block-shaped ingredients> The arranged block-shaped ingredients are joined together to form a food product having a three-dimensional structure. The joining may be performed simultaneously when the block-shaped ingredients are combined and arranged, or after the food product has been formed. Furthermore, the block-shaped ingredients may be joined temporarily when combined and arranged, and then finally joined after the food product has been formed. Edible glue can be used to join block-shaped ingredients. The glue to be used should be selected based on the type and combination of ingredients, and should allow the ingredients to adhere easily to each other. Table 1 shows examples of combinations of glue and types of block-shaped ingredients.

[0024] Table 1 Examples of block and glue combinations TIFF0007720072000001.tif46162

[0025] Edible glue is an edible paste made by dissolving the thickening agent sodium carboxymethylcellulose in water. It is used as a thickening stabilizer for making sweets and dairy drinks. To glue sticky things like jelly and yokan together, it is possible to use gelatin, which has little adhesive power, as a glue. Using gelatin as a glue is preferable because it does not affect the texture. Icing, made by mixing egg whites and sugar, is suitable for bonding rough surfaces such as cookies. Icing was originally used as a glue in baking. For bonding smooth materials such as tofu together or other combinations, it is preferable to use edible glue, which has stronger adhesive power.

[0026] Adding flavor or color to glue can be used as a seasoning or to improve the appearance of food. Also, when gluing food together, water or oil can be used as a primer to change the strength of the bond. These glues and primers can also contain nutritional elements.

[0027] There are various ways to make glue exhibit its adhesive strength, such as using thermoplastic glue that becomes adhesive when it cools, glue that becomes adhesive when the solvent evaporates, glue that becomes adhesive through a chemical reaction when two liquids are mixed, and glue that becomes adhesive not only from the glue but also from the food itself through the action of enzymes, etc. It is also possible to physically join food blocks by giving them a textured structure or a Velcro (registered trademark)-like structure that allows them to fit together without using glue.

[0028] <Post-processing of shaped food> If desired, the shaped food can be post-processed. For example, by creating blocks of food ingredients in the shape of a key and a keyhole for foods that go well together, it becomes easy to identify foods that go well together, and conversely, it becomes easy to identify foods that do not go together. You can also eliminate food waste by breaking down and reusing any blocks that you don't actually eat. [Example]

[0029] The present invention will be explained in more detail below with reference to examples, but the present invention is not limited to these examples.

[0030] Example 1 <Making block-shaped ingredients> A 3D printer (MakerBot Replicator 2) was used to create a prototype block of food material, as shown in Figure 1(a). Each protrusion on this prototype had a cube shape with a side length of 5 mm. There were 50 cubes in total, arranged in 5 columns and 10 rows. Next, food-grade silicone (HTV-2000) was poured into this prototype to create a silicone mold for a block-shaped food material, as shown in Figure 1(b). Furthermore, the following three types of block-shaped food materials were made using this silicone mold. First, we created a block-shaped food ingredient using white yokan (Figure 1(c)). Second, we created a block-shaped food product using red yokan (Figure 1(d)). Third, we created a block-shaped food product using chocolate (Figure 1(e)). For the first and second yokan, 100g of white bean paste, 1g of powdered agar, and 75cc of water were placed in a pot and heated while stirring. Once boiling, the heat was reduced to a level that would not cause the mixture to boil over, and the mixture was continued to boil for 1-2 minutes. The mixture was then poured into a silicone mold and allowed to cool and harden. For the second yokan, the mixture was colored with red food coloring after boiling, then poured into a silicone mold and allowed to cool and harden. The third chocolate was made by melting a chocolate bar in a double boiler, pouring it into a silicone mold, and allowing it to cool and harden. The block food material of this example, which was made using a 5 mm square silicone mold, had a roughly cubic shape with a side length of about 4 mm.

[0031] <Food shaping> First, an image was created in a 13 x 14 pixel area to serve as the data for creating the food (Figure 2). The data was created using Block Maker (registered trademark) sold by Andor Co., Ltd. Next, the three types of block-shaped food ingredients prepared as described above were combined and arranged so as to have a positional relationship corresponding to the image data. Furthermore, the block-shaped ingredients arranged with edible glue were joined together to create a food with a three-dimensional structure (Figure 2).

[0032] Example 2 <Making block-shaped ingredients> An additional fourth block of food material (green yokan) was produced using the mold for the block of food material produced in Example 1. The production method was the same as for the first and second yokan, except that green food coloring was used.

[0033] <Food shaping> First, three-dimensional image data such as that shown in FIG. 4(a) was created, and this was then decomposed to create image data for each layer (FIGS. 3A to 3H) used when arranging block-shaped ingredients. Next, the first, third, and fourth block-shaped food ingredients prepared as described above were combined and arranged so that adjacent block-shaped food ingredients were joined together with edible glue, resulting in a positional relationship corresponding to the image data (Figures 3A to 3H). Furthermore, the food ingredients arranged on each layer were stacked and combined to form a food product with the front shown in Figure 4(b), the side shown in Figure 4(c), and the back shown in Figure 4(d) in a layout corresponding to the three-dimensional image data (Figure 4(a)) that was synthesized from the image data for each layer.

[0034] Example 3 <Making block-shaped ingredients> Instead of the fused deposition modeling 3D printer (MakerBot Replicator 2) used in Example 1, a stereolithography 3D printer (Formlabs Form 2) was used to create a prototype block-shaped food material mold as shown in Figure 5(a). Each convex portion of this prototype had a cube shape with a side length of 6 mm. There were 50 cubes in 5 columns and 10 rows. By using a stereolithography 3D printer, it became possible to create blocks with even less distortion (Figure 5(b)). In addition, when designing this prototype (Fig. 5(c)), the inside edge of the surface of the silicone mold was designed to be curved (Fig. 5(d)) to prevent the surface of the silicone mold block, which was made by pouring food-grade silicone into the prototype, from spreading due to surface tension.

[0035] Next, food-grade silicone was poured into this prototype to create a silicone mold for a block-shaped food ingredient, as shown in Figure 5(e). Furthermore, using this silicone mold, four types of block-shaped food materials were made: yellow, red, brown, and transparent. The yellow block-shaped food material was made by putting 80cc of commercially available apple juice, 10g of sugar, 10g of gelatin, and 5g of almond tofu mix into a pot, heating it while stirring until it reached around 80°C, heating it at 80°C for 2-3 minutes, and then pouring it into a silicone mold. The red and brown block-shaped food materials were prepared by heating them in the same manner as the yellow block-shaped food material, and then adding red and brown gel coloring agents, respectively. The transparent block-shaped food was made using water instead of apple juice, as was used to make the yellow block-shaped food, and without the almond jelly base or food coloring. The almond jelly base was used to make the other block-shaped food so that the blocks would not be see-through. When the material prepared as described above was poured into a silicone mold, it was cooled and solidified while leaving enough liquid to form a thin film on the surface of the mold, and after solidification, the film on the surface of the mold was wiped off with a paper cloth soaked in hot water to melt it. This smoothens the surface of the block-shaped food material, reducing problems that arise when stacking block-shaped food material due to unevenness in the block surface.

[0036] To bond block-shaped food ingredients together during food modeling, an adhesive (edible glue) was prepared by dissolving 2.5 g of gelatin in 65 cc of boiling water at approximately 80°C. The adhesive prepared in this manner is resistant to dripping and can be used without over-hardening during stacking of block-shaped food ingredients. Furthermore, this adhesive can sufficiently bond the previously placed block-shaped food ingredients to the other block-shaped food ingredients, for example, when attempting to place another block-shaped food ingredient on top of a previously placed block-shaped food ingredient by adsorbing it to the suction pad of a food modeling robot (described below), so that the other block-shaped food ingredients do not remain on the robot's suction pad. Furthermore, refrigeration after stacking block-shaped food ingredients to form the food increases the adhesive strength, preventing the block-shaped food ingredients from falling apart even when the resulting three-dimensional food is lifted or tilted. The adhesive had an edible taste and aroma.

[0037] <Food shaping> Food modeling was performed using the "DOBOT Magician" (Figure 6), a 4-axis desktop robot arm developed for STEM (Science, Technology, Engineering, and Mathematics) education and sold by Shenzhen Yuejiang Technology Co. Ltd. This robot arm has a positional repeatability accuracy of 0.2 mm and, by using the attached interchangeable jigs, is capable of performing operations such as gripping, suction hand, 3D printing, laser engraving, writing, and pen drawing. In this example, the suction function of this robot arm was used to stack block-shaped ingredients. The suction pad of the included suction hand is 20 mm in diameter, which is not suitable for suctioning 6 mm square block-shaped ingredients. Therefore, a new suction jig, as shown in Figure 7, was created. The jig was made of polylactic acid (PLA) using a 3D printer (MakerBot Replicator 2). To reduce the force applied to the block of ingredients by the jig when suctioning the block of ingredients, the jig was designed with a rubber-band-like buffer between the part connected to the robot arm and the part that contacts the block of ingredients. In addition, supports extending almost perpendicularly from the part connected to the robot arm and the rubber-band-like buffer were installed to secure the suction tube extending from the robot arm's suction mechanism. This prevents the tube from moving and pulling the jig when the robot arm moves. Furthermore, a 5 mm diameter tube made of the same material as the suction tube was attached to the tip of the jig that contacts the block of ingredients.

[0038] The data for creating the food was created using the free software VoxCAD. By clicking on the squares, a 3D model of an apple was designed as shown in Figure 8(a), and the coordinate data was saved as a text file. Next, a program was written in Python to move the robot arm to specified coordinates, and was loaded into DOBOT Studio, DOBOT's dedicated software. By loading a text file into the program, the four types of block-shaped ingredients mentioned above were stacked to create a food product with a three-dimensional structure (Figure 8(b)). As can be seen from the cross-sectional design diagram shown in Figure 8(c), the four types of block-shaped ingredients were used for the apple skin (red), flesh (yellow), and stem (brown), as well as the support part (transparent).

[0039] Because DOBOT moves according to coordinate data, a plate-like frame was prepared in advance to position DOBOT, the block-shaped ingredients, and the adhesive. A pallet was also created using a 3D printer to hold the block-shaped ingredients one by one. DOBOT, the block-shaped ingredients placed on the pallet, and the adhesive were fixed in the designated positions on this frame to prevent them from shifting positions. Furthermore, to make it easier to remove the block-shaped food material from the suction pad, potato starch was sprinkled on the top surface of the block after it was placed on the pallet. The stacking of the block-shaped ingredients was carried out by repeating the following steps 1) to 4): 1) The suction function of the robot arm is used to suck up block-shaped ingredients using a suction jig (pressure -35KPa). 2) Dip the bottom of the block of food into the adhesive in the container for about 1 second. Note that this step can be omitted if there is no need to adhere the block of food. 3) Place the block-shaped food material at the position specified by the coordinate data. 4) Pressure is released from the suction jig toward the block of food material being sucked, thereby separating the block of food material from the suction jig. [Industrial Applicability]

[0040] Compared to conventional food 3D printers, this invention can use a wider variety of materials and can layer them to create three-dimensional food structures without compromising the food properties of the materials. Conventional food 3D printers require the food to be extruded from the tip of a nozzle approximately 1-2 mm in diameter, which often makes it difficult to handle food materials properly as printing materials. For example, vegetables and fruits must first be mashed and then thickened with a thickener to create a paste. This process compromises the food properties of the ingredients, such as their taste, nutrients, and texture. In the present invention, block-shaped ingredients are used to create food with a three-dimensional structure, so block-shaped ingredients can be made by cutting the ingredients or molding them using a mold, and it is possible to process the food into a food with a three-dimensional structure without damaging the properties of the food itself.

Claims

1. A food product having a three-dimensional structure formed by combining block-shaped ingredients, The block-shaped food material has a substantially cubic shape with a side length of 1 mm to 10 mm, A three-dimensional structure is formed by combining and arranging a plurality of types of block-shaped ingredients in a desired positional relationship with each other and joining them together, The food product further comprises an edible glue selected according to the type of the block-shaped food material for bonding the block-shaped food material together.

2. 2. The food product according to claim 1, wherein the block-shaped food material is formed by hardening a fluid material.

3. 3. The food product according to claim 2, wherein the fluid material is chocolate, candy, jelly, or yokan.

4. 4. The food product according to claim 2 or 3, wherein the plurality of types of block-shaped food ingredients have shapes corresponding to the shape of a mold for hardening the flowable ingredient.

5. 2. The food product of claim 1, wherein the edible glue is selected from the group consisting of gelatin and edible glue.

6. The food product according to any one of claims 1 to 5, wherein the desired positional relationship of the plurality of types of block-shaped ingredients is determined based on 3D data created in advance.

7. A method for producing a food product having a three-dimensional structure formed by combining block-shaped ingredients, A step of preparing a plurality of types of block-shaped ingredients having a substantially cubic shape with a side length of 1 mm to 10 mm; a step of combining and arranging the plurality of block-shaped ingredients so as to have a desired positional relationship with each other; a step of joining the arranged plurality of block-shaped food materials to each other to form a food product having a three-dimensional structure; Including, The method for producing the food product is characterized in that the arranged food blocks of the plurality of types are bonded to one another with an edible glue selected according to the type of food block.

8. The method of manufacturing according to claim 7, wherein the plurality of types of block-shaped ingredients are prepared by hardening a fluid raw material.

9. The method according to claim 8, wherein the fluid material is chocolate, candy, jelly, or yokan.

10. 10. The method of claim 8, wherein the fluid raw material is placed in a mold having a shape corresponding to the shape of the plurality of types of block-shaped food materials and hardened.

11. The method according to claim 7, wherein the edible glue is selected from the group consisting of gelatin and edible glue.

12. The manufacturing method according to any one of claims 7 to 11, wherein the desired positional relationship of the plurality of types of block-shaped ingredients is determined based on 3D data created in advance.

Images