Leafy green vegetables processing system

Abstract

A device for cutting and sanitizing leafy green vegetables is provided. The device has a housing a feeding chute configured to receive leafy green vegetables; a roller configured to direct the leafy green vegetables through the device; a sanitization system disposed along the feeding path and / or over a post-cutting region, and a blade assembly according to one aspect. The sanitization system includes at least one of ultraviolet light emitters or sanitizing mist nozzles. The blade assembly includes at least one blade extending radially from the roller and the configured to cut the leafy green vegetables when the roller feeds the leafy green vegetables into the device.

Description

LEAFY GREEN VEGETABLES PROCESSING SYSTEMBACKGROUND

[0001] Home gardeners and individuals who purchase fresh greens are faced with a set of steps when preparing their greens for a meal. Preparation methods of leafy green vegetables vary based size and rigidity, and it generally involves selection of leaves, cleanings separation of stems (if large stems are present), stacking, cutting of the leaves and collection, as shown in FIGs. 7A-7F. Leafy green vegetables can cut by chopping or slicing in different sizes depending on the preferred size, one of the preferred and most difficult cuts for such greens is the chiffonade cut, which is unique to herbs and leafy vegetables. The chiffonade cut is achieved by manually stacking multiple leaves together (not always), followed by a tight roll with multiple cuts applied perpendicular to the roll, as shown in FIG. 8.

[0002] Moreover, traditional methods for preparing leafy green vegetables typically involve separate washing, drying, and cutting steps.

[0003] Accordingly, manual cutting is labor-intensive and inconsistent, while conventional food processors often fail to handle delicate leafy produce efficiently and may not address microbial contamination. Indeed, existing food processors are not optimized for the fibrous structure of greens. They produce inconsistent cuts, lead to significant wastage, are labor- intensive due to the input and cleaning processes, often shred rather than slice, and typically do not distinguish between leaf and stem portions or separate them as appropriate. Additionally, few devices integrate real-time sanitization, feedback, or cleaning mechanisms.

[0004] There is no current system that is specifically configured to process leafy green vegetables in a gentle yet efficient manner while maintaining uniformity and minimizing damage to the produce, much less a device that combines cutting and integrated sanitization in a compact, automated, and efficient form factor.SUMMARY

[0005] The solution disclosed within this submittal integrates the automated functionality of a food processor yet does so in a way that addresses missing elements needed for processing and cutting leafy green vegetables with the preferred chiffonade cut. The disclosed system simplifies and incorporates automated processing of steps, including the following: Sanitizing of greens, Adjustability for cutting greens (depth for stack) width of cut in a precise manner, length of ribbon cut, Separation of stems from the greens, Collection of the separated stems, Collection of the desired processed greens, Final Rinse and drying of greens, Post cleaning of appliance, and Post Process conditioning of greens.

[0006] Embodiment of the present disclosure provide a leafy green vegetables cutting device that incorporates a feeding mechanism, a stem removal mechanism, a blade assembly, catch basins for both cut leafy green vegetables and stems, electronics (motor, controls, etc.), and a sanitization system. The sanitization system may include ultraviolet (UV) light, atomized sanitizing mist, or another antimicrobial treatment applied to the leafy green vegetables either before cutting (during feeding) and / or after cutting (as the product falls into or is retained in the catch basin). This integrated design facilitates uniform cutting, reduces microbial contamination, and enhances overall food safety and handling efficiency.

[0007] In one embodiment, the device includes a housing, a feeding chute, a feeding mechanism, a blade assembly, catch basins for both cut leafy green vegetables and stems, and one or more sanitization units positioned strategically within the feed path and / or over the catch basin. The feeding mechanism guides leafy green vegetables through a sanitization chamber or misting zone before reaching the cutting area. Optionally, UV-C LEDs or mist nozzles can also be positioned over the catch basin to treat cut greens before packaging or serving.

[0008] The present application thus discloses a countertop appliance designed for the preparation of leafy green vegetables greens or other leafy vegetables, incorporating one or more of the following elements:

[0009] Cleaning and Sanitization Subsystem - Including UV-C light sanitization (with adjustable intensity, dosage timing, and dual-surface exposure), antimicrobial misting, vapor, or water bath systems, optionally combined with a mechanical stripper brush module for active cleaning.

[0010] Adjustable Cutting Mechanism - Featuring user-defined control of ribbon width, length, and stack thickness. Blade geometry ensures slicing without tearing. Modular cutting cartridges and multiple blade heads provide cut-style customization.

[0011] User Controls & Smart Logic Integration Enables start / stop functions, cut-size selection, stack depth, and sequencing of sanitization and cutting steps through tactile, proximity, or sensor-based input. Safety lockouts, logic gates, and microcontroller sequencing manage workflow based on real-time state feedback.

[0012] Feedback and Indicators - Visual, audible, and / or tactile indicators provide system readiness, mode status, operation alerts, and maintenance needs. Integrated lighting supports both UV and visible bands to show sanitization status.

[0013] Modular Component Separation and Power Safety Lockouts - Detachable cutter heads, catch basins (for both leaves and stems), and removable access covers with integrated safety switches enable cleaning, maintenance, and portability. Spring-loaded axial motor couplings enable rapid reassembly with power isolation.

[0014] Leaf / Stem Separation - A geometry-based intake system aligns leaves for proper stem-to-blade orientation. Separate pathways or collection bins segregate leaf and stem portions.

[0015] Power and Communication System - Incorporates AC / DC conversion, high- and low-voltage logic control, integrated circuit protection, and sensor wiring throughout. Sequential enablement of functions ensures safety and consistency.

[0016] Variants and Enclosure Design - Models may be manual, electromechanical, or embedded with electronic logic. The outer aesthetic shell is cleanable, ergonomically designed,and may be independent or integrated with the structural chassis. Enclosure design ensures airflow, restricts UVC exposure, and blocks access to moving parts.BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 illustrates feeding leafy green vegetables to a leafy green vegetables processing system, according to one embodiment.

[0018] FIG. 2 illustrates an exploded view of a leafy green vegetables processing system, according to one embodiment.

[0019] FIGs. 3A, 3B, and 3C illustrates sanitization systems of a leafy green vegetables processing system, according to one embodiment.

[0020] FIGs. 4A, 4B, 4C, 4D, 4E, 4F, 4G, 4H, 41, 4J, 4K, 4L and 4M illustrates systems and methods of applying the sanitization systems of the leafy green vegetables processing system, according to embodiments.

[0021] FIGs. 5A, 5B, 5C, 5D, 5E, 5F, 5G, 5H, 51, 5J, 5K, and 5L illustrates systems and methods of operating the leafy green vegetables processing system for a variety of cut-width and cut-to-length configurations, according to embodiments.

[0022] FIGs. 6A, 6B, and 6C illustrates different methods of power and levels of electrical systems of a leafy green vegetables processing system, according to one embodiment.

[0023] FIGs. 7A, 7B, 7C, 7D, 7E, and 7F illustrates methods of manually cutting leafy green vegetables.

[0024] FIG. 8 illustrates a chiffonade cut.

[0025] FIGs. 9A and 9B illustrate nested subassembly separation of mechanics and electronics for cleaning, according to one embodiment.

[0026] FIGs. 10A, 10B and 11 illustrate user interface variants, according to one embodiment.

[0027] FIGs. 12A and 12B illustrate a system diagram of the control s / circui try, according to embodiments.

[0028] FIG. 13 illustrates a perspective view of a leafy green vegetables processing system with UVC, according to one embodiment.

[0029] FIG. 14 illustrates a perspective view of a leafy green vegetables processing system with an inlet auto feed light curtain, according to one embodiment.

[0030] FIG. 15 illustrates a perspective view of a leafy green vegetables processing system showing airflow for heat management, according to one embodiment.

[0031] FIGs. 16A, 16B, 16C, 16D, 16E, and 16F illustrates graphs of motor currents versus torque loads at various voltage settings for an auto-stop and reverse, according to embodiments.

[0032] FIGs. 12A and 12B illustrate motor coupling and removing with the rollers, according to embodiments.

[0033] FIGs. 18A and 18B illustrate power removal switch concept for access covers and bin removal, according to embodiments.

[0034] FIGs. 19A and 19B illustrate an access cover removal, a power removal switch, and removal of cutting mechanism according to embodiments.

[0035] FIGs. 20A, 20B, 20C, and 20D illustrate removal of the catch basins and substituting a cleaning insert for power clean, according to embodiments.

[0036] FIGs. 21A and 21B illustrate an inlet access cover with integrated functionality for feed and flex for removal of power, according to embodiments.

[0037] FIGs. 22A, 22B and 22C illustrate side and top cross-sectional views of the leafy green vegetable processing system, according to one embodiment.

[0038] FIGs. 23 A, 23B, 23C, and 23D illustrate leaf cutting and separation of stems with integrated cut-to-length of stems, according to embodiments.

[0039] FIG. 24 illustrates a perspective view of a portion of a leafy green vegetables processing system showing vertical engagement of power mechanism for customer removability, according to one embodiment.

[0040] FIG. 25A illustrates a perspective view of a leafy green vegetables processing system, according to one embodiment.

[0041] FIGs. 25B and 25C illustrate cross-sectional views of the leafy green vegetables processing system of FIG. 25 A, according to one embodiment.

[0042] FIGs. 26A and 26B illustrate a front views of the leafy green vegetables processing system with and without sanitization, according to one embodiment.

[0043] FIG. 27 illustrates a front view of the user interface using dials for controlling a leafy green vegetables processing system, according to one embodiment.DETAILED DESCRIPTION

[0044] Embodiments disclosed herein are directed to a leafy green vegetable processing system that address one or more of the challenges noted above. Specifically, various embodiments of the present invention relate to a countertop appliance designed to automate the preparation of leafy green vegetables — such as collard greens, kale, mustard greens, and other similar produce — by integrating sanitization, stem removal, cutting, collection, and postprocessing in a compact, user-friendly system. The device improves upon traditional food processors by accommodating the unique structure and preparation requirements of leafy green vegetables, including precision chiffonade-style cutting and post-cut sanitization. It should be noted that term “leafy greens”, “greens” or “leaves” are intended to mean leafy green vegetables.

[0045] Generally, and as will be described in more depth herein, the leafy green vegetable processing system 100 may be a countertop appliance that is for residential use (but could be modified or applied to a commercial setting as well). The leafy green vegetable processing system 100 is configured to first clean leafy green vegetables and / or destem the leafy green vegetables, and the leafy green vegetable processing system also includes a series of blades spaced apart to cut the leafy green vegetables in equal strips, in some embodiments. The various functional subsystems are designed for flexibility of use. The product is tailored for a recommended use case with collard greens but can be utilized to cut all leafy green vegetables. Various details and embodiments of the leafy green vegetable processing system 100 are provided below which reference FIGs. 1-27.

[0046] As shown in FIG. 1, the processing system 100 includes a feeding system 101, a cutting head / cutting system, a housing 108, electronics / control system / power 109, and catch basins 104, 104’.

[0047] The main housing 108 made of food-safe material, which houses the functional components of the device. The housing 108 fully encloses the rollers and an area 144 (note 144 denotes a specific wedge and is part of an area which is not uniquely identified by number) where the greens will be cut, as shown in FIGs. 25A-C.

[0048] Next, leafy green vegetables (or “greens” for short) 106 are fed into the feeding system 101 flat and with or without stems. The feeding system 101 is positioned at the top or side of the housing 108 and is configured to receive the leafy green vegetables in either loose or bundled form. The feeding system 101 may include a series of rollers 103 which grabs the leafy green vegetables 106 to present the leafy green vegetables 106 to the cutting heads / system 102. The feeding mechanism may include a motorized or manual pusher or roller system that gently guides the greens toward the cutting blades without compressing or bruising the leaves.

[0049] At the core of the system is a set of rotating or oscillating blades, which may be configured in a circular, straight, or cross-hatch pattern. These blades are specifically designed to slice through delicate leafy material cleanly and consistently, reducing damage to the cell structure and preserving freshness. The cutting heads / system 102 include a blade or cuttingheads which are configured to rotate with the rollers so that when the rollers are rotating the greens 106 will be cut. As is described herein, the blades on the rollers may be adjustably spaced in a manner that the greens will be cut into strips.

[0050] It should be understood that the leafy green vegetables 106 may be any vegetable that is configured to be cut into strips, such as lettuce, collard / mustard / etc. greens, kale, or any other consumable leaves. It should also be understood that the greens may or may not have stems and the present system is configured to process the greens with or without stems.

[0051] Beneath the cutting assembly 102, a leaf catch basin 104 is positioned to collect the chopped or sliced greens while there is a stem catch basin 104’ to catch the separated stems. The basin may be removable for easy transfer and cleaning and may feature drainage holes or mesh lining to remove excess moisture, which may be needed for maintaining product quality and shelf life.

[0052] There may be other features as well, including optional features such as adjustable blade settings to vary the size of the cut, safety interlocks, anti -jamming mechanisms, and components that are dishwasher-safe for ease of maintenance. Adjustability shall be accommodated using various models and part change-outs to affect width and depth of cut. It will also affect the overall dimension of the product, affecting counter space, height and the need for integrated catch basins, versus the use of standard bowls and plates. These features are discussed in more detail later herein.

[0053] When a user wants to cut leafy green vegetables, the leafy green vegetables should be washed and / or clean and be generally clean of debris prior to processing. At the processing system 100, the leaves 106 are inserted flat or folded along the stem. Indicators on the leafy green vegetable processing system 100 direct the user to align the stem of the leaf to the appropriate location of the cutter feed-head 102. Note that there may be multiple feed heads 102. The appliance separates the stem from the leaf by a specific stem-cutting blade, channeling the stem through a specific chute directed by separator 144 which is aligned to lower edge of the stem-cutting blade to a catch-basin. At the same time, the processing system (also referredto as “processor”) 100 cuts the leaf into equally spaced ribbons which directly fall into a separate catch basin 104, as shown in Figures 22-23.

[0054] According to some embodiments, the processing system 100 has provisions to affect sanitization of the leaves 106 prior to or during cutting of the leaves, as referenced in Figures 3, 4, 13 and 26. The sanitization feature 110 treats or sanitizes the leaves as part of the process of cutting the leaves. The appliance may achieve sanitization through a variety of features 110, including UV light, applied vapor technologies and liquid solution misting (see FIGs. 3A-3C). This may occur either before or after the cut, as described above. Use of applied vapor or mist technology shall involve a unique reservoir and a delivery system to apply vapor or mist to the surface of the leaves. The catch basin 104, used to collect the processed greens may incorporate a dual basket for bathing and drying as part of the sanitization process. Such systems shall incorporate a means of delivering and extracting the cleaning solution. It shall utilize pumps, piezo-electric ultrasonic vaporizers, gravity drain and centrifugal force. Geometry shall contain vapors and mist in a manner that routes excess solution into the catch basins.

[0055] Details of sanitization by UVC may be as follows. The system 100 may include one or more UVC LEDs in the housing which are configured to be proximate or adjacent to the cutting heads. The exact locations of sanitizing emitters may be optimized for effect. Shrouds and guttering of specific materials shall protect the users from UVC light exposure. Sanitization by UVC is a function of several factors including direct line-of-sight between the light emitter and the sub straight surfaces to be sanitized, intensity of the light per exposed area and the total accumulated time of UVC exposure. In order to accomplish the targeted level of sanitization, all system elements are integrated. In this regard, the UVC LEDs may be employed as shown in FIG. 3B where the leaves are exposed to the UVC LED light within the housing of the system 100 just to the leaves being cut by cutting heads also located in the housing.

[0056] A UVC exposure zone is created by placing light emitters outside of the zone (but in the housing), yet shining light through clear windows 111 of a particular material which properly pass all targeted wavelengths of UVC light 110 without lost efficiency, as shown in FIG. 13. The remaining enclosure materials of the zone do not pass UVC light. The UVC exposure zone completely contains all UVC, preventing light from escaping the product.

[0057] Light emitters are positioned such that the light is dispersed across an exposure zone. Light shines on both front and back of each substrate that travels through the exposure zone. For example, as shown in FIGs. 4A-4 , light emitters are shown as positioned on both sides of the leafy green vegetables 106 whether it be before or after the greens 106 are cut.

[0058] UVC Light emitters may be powered to a specific intensity per exposure area within the exposure zone. This may be set by the user or automatically determined based on the speed and size of the leafy green vegetables being fed into the feeder.

[0059] Each substrate of leafy green vegetables 106 moves through the exposure zone at a controlled rate such that the intensity, multiplied by total exposure time, matches targeted UVC dosage for cleaning and sanitation.

[0060] Movement of the substrate relative to UVC emitter sources exposes the substrate of greens 106 to various angles, providing better overall coverage of surfaces.

[0061] FIGs. 4H-4K illustrate the progression of the cutting of leafy green vegetables when being presented to the system 100. At FIG. 4H, at time tl, the leafy green vegetables 106 are inserted into the rollers. The rollers feed the leafy green vegetables and also include cutting heads that cut while the rollers are rotating. At time t2 in FIG. 41, the greens 106 are cut while the rollers continue feeding other portions of the greens 106 to the system 100. Additionally, the sanitizing features 110 clean and sanitize the greens after they have been cut and while the other portions of the greens 106 are fed to the system 100 using the rollers.

[0062] At time t3 in FIG. 4J, the greens 106 are fully cut and are being sanitized. Then, at FIG. 4K, the greens 106 are fully cut and cleaned and are sent to the catch basin. At this point, the greens have been cut into strips of a predetermined width along the full length of the greens 106.

[0063] It should be noted that the width of cutting of the greens is determined by the width of the blades 103. In some embodiments, the desired width of the strips (and thus, the width between blades in the system) is between 1-10 millimeters, between 2-4 millimeters, about 3millimeters, between 1-2 millimeters, between 0-1 millimeters, or any other width amount as this width is adjustable as discussed herein.

[0064] Flexibility of use is enabled by adjustments of the processing system 100 at set-up. There are several areas to accommodate this flexibility. Users may prefer to stack multiple greens for speed and efficiency. Additionally, the preference of cut width may be adjusted for wide or narrow ribbons by lateral movement of the blades, replacement of the blades or replacement of the cutting head cartridge, referenced in Figure 5. For example, FIG. 5 shows how the blades can be adjusted to cut at differing widths, Wl, W2, W3, etc.

[0065] The cutter head itself may be adjusted relative to the catch basin to allow for larger and smaller basins, depending on the job. A range of adjustments are enabled by set-up and selection of the cutter head, cut depth, cut width and height of cutter head. The specific cutting edge, in relation to other blades and fixed geometry shall allow for cutting, rather than tearing of the leaves. Rotational elements shall be engaged to one another in a manner that allows leaves to separate into ribbons. Certain models will allow for cutter head adjustability within a single head, affecting width and depth of the cut. Other models will allow for change-out of cutting head assemblies to affect cut width and depth. Cutting wheels shall incorporate mechanisms to maintain separation of the leaves from the cutter wheel, following the cut. Such mechanisms are needed to prevent the ribbons from clinging to the wheels after being cut.

[0066] For example, the blades 102 are shown in FIG. 5 as overlapping a cutting width CW 1 and CW2. The planned clearance gap must be maintained for the greens to passPGl and PG2. In this regard, when the roller 103 rotates, the blades 102 are configured to cut through the leafy green vegetables, and to do this the blades on opposite sides must not only meet at a point but also extend so as to overlap each other by a cut depth CW 1 and CW2. In this regard, this allows a clean and full cut of the leaves. This cutting width CW1 and CW2 is adjustable so as to cut leaves of varying toughness and thickness. For example, for thin leaves with little fibrous material and easily cut leaves, the cutting width CW1 and CW2 may be almost zero (or exactly zero) since it would not take much to cut these leaves, but for leaves which are thick or tough with connected fibrous material, more overlap between cutting edges is required andwith a higher cutting width CW 1 and CW2. The working range of CW 1 and CW2 is approximately0.015 - 0.250 inch, in one embodiment, 0.1 to 0.2 inches, in one embodiment, or 0.125 inches, in one embodiment. . In all cases, planned clearance gap PG1 and PG2 should be maintained to allow greens to pass with a minimum of 0.0625 inch. The planned gaps and cut depth are determined by the major diameter of the cutting cylinder (cutting roller portion), the minor diameter of the cutting cylinder (core roller portion) and the distance between each axis of opposing cylinders. In other words, the ends of the cutting roller portion (major portions) of one roller do not touch the core roller portion of the other roller so that there is a gap therebetween. Such gap allows for the greens to pass through without being compressed or smashed between the rollers and the only portions being touched by the rollers are the cutting roller portions of both rollers. It should be noted that this gap may be variable by having a roller with cutting roller portions varying major diameters so that when the major diameter rollers are inserted, the gap between the cutting roller portions and the core roller portions are increased in the event that multiple leaves are stacked together and run through the system at one time (so that multiple leaves are cut simultaneously).

[0067] The total length of the cut-ribbon is managed by one of several ways, as shown in FIGs. 5E-5H. One way is through an integrated wheel cutting method. The rollers 103 have cylindrical roller portions 112 that are spaced apart, as shown in FIG. 5E. These cylindrical roller portions 112 have a blade on the edge thereof to cut the strips into vertical strips that extend the complete length of the greens 106 being cut. It should be noted that the roller portions have two portions - a portion with a “Major” diameter (a diameter greater than a predefined amount) and a portion with a “Minor” diameter (a diameter lesser than a predefined amount) (See FIG. 5B). The overlap between the “Major” diameter portion (referred to herein as “cutting roller portion”) and the “Minor” diameter portion (referred to herein as “core roller portion”) is known as the width CW1, CW2 shown in FIG. 5B. Moreover, as shown, there are two rollers - a left roller and a right roller — that work together to feed the greens through the system. The cutting roller portion of one roller (e.g., the left roller) and the cutting roller portion of the other roller (e.g., the right roller) overlap at an interface so that when leafy greens are disposed between, the greens are cut at the interface. The edges of the cutting roller portions of the two rollers may or may not have blades on them - indeed, if they do not have blades, thecutting roller portions may each just have a right angle that meet together at the interface and are configured to tear or cut the greens at such interface.

[0068] Additionally, the cylindrical cutting head has added cutting blade protrusions 114 that extend radially out from the center of the cylinder. The width of the cutting protrusions matches the width of the ribbon. Each protrusion 114 contacts the opposing wheel 112’ once per revolution. When the cutting blade protrusion 114 contacts the opposing wheel 112’, the cutting blade protrusion 114 cuts the ribbon of greens 106 to a length that is less than the full length of the greens before being cut. The count of cutting protrusions per 360° revolution of the roller 112 may be changed to obtain longer or shorter cuts of each ribbon. Placement of multiple cutting protrusions 114 along the axial direction of the cylinder / roller 112 may be aligned across the length of the cylinder, or they may be offset to minimize the drive torque requirements through mechanical advantage.

[0069] It should be noted that the cutting protrusions may be located at multiple locations on a single roller, as shown in FIGs. 23A and 23D. For example, one cutting protrusion 114 may be locates on the roller at a first point, and another cutting protrusion 114’ located on an opposing side of the roller as shown in FIG. 23D. Greens 106 are then cut into ribbons that are one half of the length if there is only one cutting protrusion 114.

[0070] Another way to manage the total length L of each of the ribbons is through a cutting mechanism 119 which is separate from the cylindrical ribbon cutter, as shown in FIGs. 5I-5L. The cutting mechanism 119 is comprised of opposable blades 120 (FIG. 23D) which can be cycled at any frequency to cut ribbons to length L. For example, FIGs. 5K to 5L shows the opposable blades 120 open (FIG. 5K) and closed (FIG. 5L) and this process repeats at a particular cycle which is dependent on the speed of the greens 106 and the desired length L of the strips of the greens 106. In this regard, the frequency with which the cutting mechanism 119 is cycled determines the length L of ribbons. Accordingly, the greens 106 are cut into ribbons by the cylindrical wheels and pass through the opposing cutter mechanism which resides in the pathway through which the ribbons pass. Note that certain models may separate the methods of cut-to-length as it applies to the stem versus the thin leaf such that the stem may be cut on short segment while the leaf 106 is cut in longer segments (Figure 23).

[0071] The control of the processing system 100 includes electronics / controls 109 affecting the on / off function of the processing system 100 (as shown in Figures 10-12 and 27). The electronics / controls 109 may include a motor, an on / off switch, circuitry to control the motor, and / or a power variability control to control the power / resistance to a circuit, where the circuit with components such as a microcontroller / processor, memory, and logic stored in the memory.

[0072] Adjustability may be managed manually but may also be integrated into automated controls. For automation, input is needed from the controller to drive outputs, such as solenoids and motors to adjust physical placement of components. Power applied to the cutting blades may be managed through a proxy sensor 131, which turns power on / off automatically based on presence of leaves at the inlet of the feed (see Figures 9, 14, and 22). This may be accomplished using a source 132 and the sensor 131 sensing the output (e.g., light) of the source indicates no leaves are being fed but when the sensor no longer senses the source output, this indicates to the system 100 that there is a leaf in the feeder 101 and thus, turning on the motor to feed the leaf. Adjustability of motor on / off in relation to the light sensor is adjusted such that the leaf continues its feed and cut to completion, which surpasses the time the light curtain changes state.

[0073] Other methods may require tactile switches. To enhance safety, there may be one of several methods to prevent unintended feed of items into the cutter head. One method is to incorporate a physical bar across the inlet. When the bar is depressed, power is removed from the cutting heads. A second way is to integrate a momentary on-button, which is normally off. It must be held at the on-position to operate. The cutting head is powered only while the switch is held to the on-position. A third way is to sense the difference of a human hand, versus that of a leaf using capacitive / electrical characteristics. Sensor feedback is used to remove power when the profile does not match that of the leaves. A fourth way to manage safety is to incorporate a lock-out of all functions. Unlocking may require one of many methods, such as a key-dance or a press-and-hold key. Geometry of the housing shall restrict access to cutting blades. Should access be allowed to the blades, it shall be accompanied by access panels and integrated reservoirs, which when removed, shall cut power to the motion mechanisms, including cutting blades. Additionally, forced entry to the cutting mechanism past therestrictive inlet at the feeding device 101 shall cause flex of the protective cover, contacting a switch 121 which disables power (Figure 21).

[0074] Indicators shall be incorporated into the appliance to communicate with the users. It shall communicate the on / off and ready status of the appliance. Additionally, sensors shall indicate which mode of operation is active, such as processing, adjusting, sanitizing, draining, self-clean mode, service, empty bin, cut length, errors codes, ready mode and sleep mode. Normal operations shall be tracked, such that abnormally high motor torque and associated current draws shall trigger a response. That response shall be automatic reversal of the motor for a period of time and indicators which shall communicate need to service the blades assembly. Adjustability of the system shall allow for customized threshold of torque limits based on standard set-up and normal usage patterns. (See Figures 10-12, 16 and 27.)

[0075] Various functions of the appliance shall be grouped together in modules for the purpose of assembly and removal. The rollers include cutting blade assembly modules which may be removed for various reasons, including change-out for cut style, cleaning, portability and to empty reservoirs and catch basins. In other words, the rollers can be changed to allow for varying cutting widths of the greens. Specifically, the cutter head shall be modularized for interchangeability with other heads to affect cut type. It shall also be modularized for general removal and separation from power, needed for cleanability. Both the catch basin and stem basin shall be modularized for removal to empty or to transport greens to an area away from the processor. Removal of cutting blade assembly module shall be assisted in the following ways.

[0076] As shown in FIG. 17A-17B, the drive train between the motor 122 and rotating blades 114 shall incorporate couplers 127 which engage and disengage to one another. The couplers may have spring 125 assist and motion relative to mounting, which allows for maneuvering during removal and installation (see FIG. 17B). The spring 125 allows for the couplers 127 to engage when there is relative rotation between the two couplers 127. Additionally, there may be pivoting and locking mechanisms 123 to ensure proper location of the cutting assembly to the drive train and product housing.

[0077] The cutting blade assembly module also has a cut-to-length blade 119. It shall be comprised of opposing blades 120 (FIG. 5E-5H), driven by one of several motion mechanisms, including one or more solenoids. The solenoids shall be configured in a push or a pull configuration. For removability, the cutting blade assembly module shall not contain any electrical components, such as wiring, motors, solenoids, LED’s or light emitter / receivers. Electrical componentry shall remain with the product housing and chassis, as shown in Figures 9, 19, 20 & 24.

[0078] Communication and power transfer is required between functional parts. Communication shall be accomplished using hard-wired low voltage between sensors and printed circuit boards. Outputs, such as solenoids and motors shall be wired from printed circuit boards. Mechanical power transmission to the cutting head shall incorporate gears, linkage and couplers. The coupler shall be finished in a manner which allows ease of interaction with users and cleanability. The electrical models of the appliance shall receive power from an outlet and shall convert high voltage supply to low voltage within the appliance, as needed. Variation of standard power converters shall accommodate regional differences of available high voltage supplies of 110VAC and 220-240VAC. Power conversion may be incorporated into the power cord or may be integrated into the controls section of the appliance. Additionally, GFCI may be integrated into the power cord or into other circuity of the appliance.

[0079] The system 100 shall have model variants, as depicted in Figure 6, 25 & 26. At the lowest price point, there may be a system 100’ having hand-power 124 for the cutting head which does not require electricity. Mid-range models 100” shall be powered by high voltage without electronics. At the top end, models 100”’ shall incorporate low voltage electronics as described above herein.

[0080] In the case of the high voltage variant system 100”, electrical power conversion is not required, where there is no microcontroller for logic. All controls may be high voltage electro-mechanical switches, which are wired directly between power supply and outputs, such as motors and solenoids. Safety bars may break the electrical circuits to remove power to the cutting head.

[0081] The variant model 100”’ with low voltage shall incorporate AC / DC power conversion, micro-controllers, input sensors, output indicators, outputs for motors, pumps, piezo electric ultrasonics and solenoids. There may be logic to manage all the input / output (I / O) as well as lock-out protocols. Additionally, there may be safety bars which may break the electrical circuit to remove power to the cutting head as in Figure 21.

[0082] Product aesthetics shall be managed by exterior parts. Attention shall be placed on cleanability and ease or model variation by visual distinction. In certain model variants, the aesthetics components shall be separate from the chassis, while other model variants may incorporate the chassis functionality with aesthetics.

[0083] The chassis shall serve as the structure element of the appliance and shall serve as a stable mounting base of the product to the countertop, yet also as serve as a mounting member for the various functional modules, and components of the product. Many functions shall be integrated into the chassis or housing, such as designated channels for wire, air route and tube routes. It may also include surfaces for component mounting and adjustability for ergonomics of the appliance (see Figures 15 and 22)

[0084] Cleaning and maintenance of the appliance shall be enabled by several design elements, as shown in Figures 20 and 21. Certain model variants shall have sanitizing features which shall be activated for a period of time to assist in cleaning. All catch basins 104, both for desired greens and for stems, shall be removable for cleaning. The cutter head may be removable for cleaning as well. The surfaces of the appliance shall be smooth and continuous as to avoid crevasses for debris to collect or inter into parts of the appliance which are difficult to clean. Lower extremities of component and structural enclosure shall have weepholes to prevent water collection.

[0085] It should be noted that the system 100 is configured to remove the stems 150 from the leaves 106. This may be done by the leafy part of the leaves 106 to be folded at the stem 150 and the folded leaf is then inserted into the system 101. This makes the stem 150 be on the end of the folded leaf. As shown in 23 A, one of the blades 102 will cut the stem 150 from the leaf 106. Then a separator 144 directs the cut stem 150 to the stem catch basin 104’.

[0086] It should be understood that the stems could be removed in other methods as well. For example, the leaves 106 could be fed into the feeder so that the stem feeds into a set location that then guides the leaves 106 so that the stem 150 feeds in between two blades and is then guided into the stem catch basin 104’.

[0087] Aspects of the described embodiments are described herein with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer readable program instructions.

[0088] These computer readable program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions / acts specified in the flowchart and / or block diagram block or blocks. These computer readable program instructions may also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and / or other devices to function in a described manner, such that the computer readable storage medium having instructions stored therein comprises an article of manufacture including instructions which implement aspects of the function / act specified in the flowchart and / or block diagram block or blocks.

[0089] The computer readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions / acts specified in the flowchart and / or block diagram block or blocks.

[0090] The flowchart and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments. In this regard, each block in the flowchart orblock diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and / or flowchart illustration, and combinations of blocks in the block diagrams and / or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.

[0091] Product usage shall be tracked in a manner that accumulates total greens processed. It will do this through calculations that account for user selections, and throughput based on the diameter of the cutting wheels, the on-time of the motor, and status monitoring of the light curtain. Tracking information of the product may be communicated to an external device using standard communications.

[0092] While the foregoing is directed to one or more embodiments, other and further embodiments may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.

Claims

CLAIMSWhat is claimed is:

1. A device for cutting and sanitizing leafy green vegetables, comprising: a roller configured to direct leafy green vegetables through the device; a sanitization system disposed along a feeding path and / or over a post-cutting region, the sanitization system including at least one of ultraviolet light emitters or sanitizing mist nozzles; and a cutting assembly comprising at least one cutting portion extending radially from the roller and the configured to cut the leafy green vegetables when the roller feeds the leafy green vegetables into the device.

2. The device of claim 1, wherein the sanitization system comprises one or more UV-C LEDs positioned within a housing of the device.

3. The device of claim 1, wherein the sanitization system includes misting nozzles configured to spray a food-safe antimicrobial solution onto the leafy green vegetables.

4. The device of claim 1, wherein the sanitization system includes a second sanitization zone positioned over the catch basin.

5. The device of claim 1, wherein the sanitization system is activated automatically by sensors detecting movement of greens through a feeding area of the device.

6. The device of claim 1, wherein the catch basin includes drainage perforations or a mesh lining to remove residual moisture from the cut greens.

7. The device of claim 1, further comprising user controls configured to adjust blade speed, cut size, feed rate, and sanitization intensity.

8. A device for cutting leafy green vegetables, comprising: a roller configured to direct leafy green vegetables through the device; a blade assembly comprising at least one blade extending radially from the roller and the configured to cut the leafy green vegetables when the roller feeds the leafy green vegetables into the device so that the leafy green vegetables are cut into strips extending a full length of the leafy green vegetables; and a de-stemming system comprising a blade located proximate to an outer portion of the roller and configured to cut the stem from the leafy green vegetables when the leafy green vegetables is folded and fed into the roller9. The device of claim 8, wherein the blade assembly includes a system to allow a width between the blades to be adjustable so that the width of cuts of the leafy green vegetables can be varied.

10. The device of claim 8, further comprising a sanitization system disposed along a feeding path and / or over a post-cutting region, the sanitization system including at least one of ultraviolet light emitters or sanitizing mist nozzles.

11. The device of claim 8, further comprising a catch basin disposed below the blade assembly to collect the cut the cut greens and stems12. A method for cutting leafy green vegetables into ribbons, comprising: receiving, via a leafy green vegetables processing system, a leafy green vegetable having a stem and a leaf; moving, via two rollers, the leafy green vegetable through the system, each of the two rollers comprising a series of cutting roller portions that each extend radially from the roller by a major diameter and a series of core roller portions that each extend radially from the roller by a minor diameter that is less than the major diameter; and cutting, using the series of cutting roller portions, the leafy green vegetable when therollers feed the leafy green vegetable into the system so that the leafy green vegetable is cut into strips extending a full length of the leafy green vegetable.

13. The method of claim 12, further comprising sanitizing the leafy green vegetables using a sanitization system disposed along a feeding path and / or over a post-cutting region, the sanitization system including at least one of ultraviolet light emitters or sanitizing mist nozzles.

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