Blender container assemblies for use with a blender base having a direct drive

Abstract

A blender container assembly for use with a blender base having a direct drive includes a container having an internal surface defining a cavity and a blade disposed within the cavity and mounted to the container. The blade is rotatable relative to the container. The blade includes a shaft configured to be directly driven by an electric motor of the blender base and a cutting portion extending radially from the shaft and defining a blade diameter. The cutting portion is spaced from the internal surface of the container by a gap distance. A ratio of the blade diameter to the gap distance is from 1.0 to 2.75.

Description

VMX0318W0 / 131951 -777 PATENTBLENDER CONTAINER ASSEMBLIES FOR USE WITH A BLENDER BASEHAVING A DIRECT DRIVECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present disclosure claims the benefit of U.S. Provisional Patent Application No. 63 / 682,871, filed August 14, 2024, entitled “Blender Container Assemblies for Use with a Blender Base Having a Direct Drive”, the entirety of which is incorporated by reference herein.TECHNICAL FIELD

[0002] The present specification generally relates to blender container assemblies for blender systems and, more specifically, blender container assemblies for use with blender bases having a direct drive.BACKGROUND

[0003] Blenders are used to prepare food items by performing a blending operation on foodstuff. A blender may include a container for receiving foodstuff and a blade assembly that is rotatable to blend the foodstuff received within the container. The blender container may include a working volume that is defined by the volume of space within the container that is generally exposed to the blade assembly. In other words, the working volume is the volume of space that foodstuff may be received within the container for blending.

[0004] Containers with a larger working volume (e.g., one or more gallons) often require a blender base having speed reduction components (e.g., gear box, belt drive, etc.) to effectively process the foodstuff into smooth consistencies. However, the use of speed reduction components increases the weight and cost of the blender base, due to the inclusion of the additional components. Furthermore, blender bases that utilize speed reduction mechanisms have slower blade speeds than direct drive blender bases, which prevents use for certain blending operations, like emulsification.VMX0318W0 / 131951 -777 PATENTSUMMARY

[0005] In one aspect, a blender container assembly for use with a blender base having a direct drive includes a container having an internal surface defining a cavity and a blade disposed within the cavity and mounted to the container. The blade is rotatable relative to the container. The blade includes a shaft configured to be directly driven by an electric motor of the blender base and a cutting portion extending radially from the shaft and defining a blade diameter. The cutting portion is spaced from the internal surface of the container by a gap distance. A ratio of the blade diameter to the gap distance is from 1.0 to 2.75.

[0006] In another aspect, a blender system includes a blender base having an electric motor and a blender container assembly. The blender container assembly includes a container having an internal surface defining a cavity and a blade disposed within the cavity and mounted to the container. The blade is rotatable relative to the container. The blade includes a shaft directly driven by the electric motor of the blender base and a cutting portion extending radially from the shaft and defining a blade diameter. The cutting portion is spaced from the internal surface of the container by a gap distance. A ratio of the blade diameter to the gap distance is from 1.0 to 2.75.

[0007] In yet another aspect, a blender container assembly for use with a blender base having a direct drive includes a container having an internal surface defining a cavity and a blade disposed within the cavity and mounted to the container. The blade is rotatable relative to the container. The blade includes a shaft configured to be directly driven by an electric motor of the blender base and a cutting portion extending radially from the shaft and defining a blade diameter. The cutting portion is spaced from the internal surface of the container by a gap distance. A ratio of the blade diameter to the gap distance is from 1.46 to 2.14 and varies along the internal surface of the container. The cutting portion of the blade spaced from the internal surface by a height distance measured parallel to the shaft. The height distance is from 0.5 inch to 0.710 inch.

[0008] These and additional features provided by the aspects described herein will be more fully understood in view of the following detailed description, in conjunction with the drawings.VMX0318W0 / 131951 -777 PATENTBRIEF DESCRIPTION OF THE DRAWINGS

[0009] The aspects set forth in the drawings are illustrative and exemplary in nature and not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative aspects can be understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:

[0010] FIG. 1 schematically depicts a perspective view of a blender system that includes a blender base and a blender container assembly, according to one or more aspects shown and described herein;

[0011] FIG. 2 schematically depicts a side elevational view of the blender container assembly of FIG. 1, according to one or more aspects shown and described herein;

[0012] FIG. 3 schematically depicts an exploded perspective view of the blender container assembly of FIG. 1, according to one or more aspects shown and described herein;

[0013] FIG. 4 schematically depicts a top plan view of the blender container assembly of FIG. 1, according to one or more aspects shown and described herein;

[0014] FIG. 5 schematically depicts a top cross-sectional view of the blender container assembly of FIG. 1 showing a blade diameter and a gap distance, according to one or more aspects shown and described herein;

[0015] FIG. 6 schematically depicts a side cross-sectional view of the blender container assembly of FIG. 1 showing a height distance, according to one or more aspects shown and described herein;

[0016] FIG. 7 schematically depicts a side cross-sectional view of another aspect of the blender container assembly showing a height distance, according to one or more aspects shown and described herein;

[0017] FIG. 8 schematically depicts a graph of test data showing current draw of a blender base relative to a blade diameter of a blade for four different configurations of the blade, tested in with three variations of foodstuff, according to one or more aspects shown and described herein; andVMX0318W0 / 131951 -777 PATENT

[0018] FIG. 9 schematically depicts computational fluid dynamics plots for three variations of a blender system.DETAILED DESCRIPTION

[0019] FIGS. 1 and 2 generally depict one aspect of a large capacity blender container assembly for use with a blender base having a direct drive. The blender container assembly as illustrated generally includes a container for receiving foodstuff and a blade for blending the foodstuff. Various aspects of the testing device and the operation of the testing device will be described in more detail herein.

[0020] The blender container assemblies described herein is contemplated for use with blender systems having a blender base that utilizes direct drive, while at the same time having a large capacity for foodstuff (e.g., one or more gallons). For example, the blender container assemblies described herein may be utilized in commercial settings where large batches of foodstuffs are blended at a time. Conventionally, in order to effectively process the food stuff in large capacity blender container assemblies, a blender base used with the large capacity blender container assemblies often has a speed reduction mechanism, apparatus, or the like (e.g., a gear box, a belt drive, etc.) to produce the torque in the blades to blend the foodstuff. Further, conventionally, when the use of blades greater than 3 inches in diameter are used in a large capacity format container in conjunction with a base lacking a speed reduction mechanism, apparatus, or the like, the resulting use produces high temperatures, creating a higher potential of thermal overload and damage to the motor and the electronics of the blender base. The aspects described herein overcome these limitations and deficiencies by utilizing dimensions and ratios of the blade and the container that allow for direct drive and optimal blend quality (e.g., uniformity in chopping, mixing, pureeing, etc. of the foodstuff). That is, the aspects described herein, which were otherwise previously unknown, are particular blade sizes and ratios of blade diameter to large capacity format container diameter that have been particularly optimized for use with direct drive bases that have been found to unexpectedly produce optimally blended ingredients even with the use of a direct drive base that does not incorporate a speed reduction mechanism, apparatus, or the like. Moreover, blender bases that utilize speed reduction mechanisms are heavier and more costly than direct drive blender bases due to the inclusion of the additional components. Furthermore, blender bases that utilize speed reduction mechanisms have slower blade speeds than direct drive blender bases, which prevents use for certain blending operations, like emulsification.VMX0318W0 / 131951 -777 PATENT

[0021] As used herein, the word “example” means an instance, or illustration. The word “example” does not indicate a key or preferred aspect or aspect. The word “or” is intended to be inclusive rather than exclusive unless context suggests otherwise. As an example, the phrase “A employs B or C,” includes any inclusive permutation (e.g., A employs B; A employs C; or A employs both B and C). As another matter, the articles “a” and “an” are generally intended to mean “one or more” unless context suggest otherwise.

[0022] It is noted that the terms “substantially,” “about,” and “approximately” may be utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. These terms are also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.

[0023] The blending containers described herein are generally configured to contain any material that may be mixed or blended with the components described herein. The material is generally not limited by the present disclosure, and can be any material. That is, while mixing of “ingredients,” “contents,” “material,” or “foodstuff’ may be described in various aspects herein, it is noted that the material can be non-foodstuffs including, but is not limited to, paints, epoxies, construction material (e.g., mortar, cement, etc.), and the like. Aspects of mixing containers described herein may also be utilized for medical and / or laboratory environmental purposes. Aspects of the mixing containers and mixing systems may include any household blender and / or any type of commercial mixing container and mixing system, including those with covers that may encapsulate or at least partially encapsulate the blending container. Further, commercial mixing systems may include an overall blending system, such as a modular blending system that may include the mixer along with other components, such as a cleaner, foodstuff storage device (including a refrigerator), an ice maker and / or dispenser, a foodstuff dispenser (a liquid or powder flavoring dispenser), or any other combination thereof.

[0024] Mixing or blending of material results in a mixed or blended product. Such mixed or blended products may include drinks, frozen drinks, smoothies, shakes, soups, purees, sorbets, butter (nut), dips, sauces, or the like. It is noted that various other mixed or blended products may result from blending ingredients. Accordingly, terms such as “blend” or “mix” may be used interchangeably unless context suggests otherwise or warrants a particularVMX0318W0 / 131951 -777 PATENT distinction among such terms. Such terms are not intended to limit any possible mixing products and should be viewed as examples of possible mixed products.

[0025] As used herein, phrases that utilize words such as “process,” “program,” and the like are used interchangeably unless context suggest otherwise or warrants a particular distinction among such terms. A process, such as a blending process, may include a series or sequence of blender settings and operations to be carried out by the blender systems described herein. In an aspect, a blending process may include at least one motor speed and at least one time interval for the given motor speed. For example, a blending process may include a series of blender motor speeds to operate the blender blade at the given speed, a series of time intervals corresponding to the given motor speeds, and other blender parameters and timing settings. The blending process may further include a ramp up speed that defines the amount of time the motor takes to reach its predetermined motor speed. The blending process may be stored on a memory and recalled by or communicated to the blending device.

[0026] Referring now to the drawings, FIG. 1 schematically depicts a blender system 20 for blending foodstuff (e.g., edible materials that are used as food or prepared for use as food). The blender system 20 includes a blender container assembly 22 for receiving the foodstuff and a blender base 24 that drives the blending of the foodstuff by rotational motion. The blender container assembly 22 may be disposed upon and in engagement with the blender base 24 as shown in FIG. 1 to perform the blending of the foodstuff. The blender container assembly 22 may be selectively removed from engagement with the blender base 24 for serving of the foodstuff, transport of the foodstuff, cleaning of the container, etc. Furthermore, the blender container assembly 22 may be configured to be placed upon another surface (e.g., a tabletop) allowing for the use of the blender container assembly 22 as general vessel for the foodstuff.

[0027] With reference to FIGS. 2 and 3, the blender container assembly 22 includes a container 26 having an internal surface 28 defining a cavity 30 and an external surface 29 disposed opposite the internal surface 28. The container 26 may extend along an axis A between a first end 32 configured to mount to the blender base 24 and a second end 34 configured to selectively receive the foodstuff in the cavity 30. More specifically, the container 26 may define an opening 36 into the cavity 30 for placing the foodstuff in the cavity 30. Accordingly, the second end 34 is configured as an open end and the first end 32 is configured as a base end. The container 26 includes a container base 31 disposed at the first end 32 and aVMX0318W0 / 131951 -777 PATENT sidewall 33 circumferentially surrounding the container base 31 about the axis A and fixed to the container base 31. The sidewall 33 extends from the first end 32 to the second end 34.

[0028] The blender container assembly 22 may further include a handle 35 coupled (e.g., fixed or removably attached) to the container 26 and extending from the external surface 29 of the container 26. The handle 35 is configured to be grasped by a user of the blender system 20. The handle 35 provides for ease of engagement of the blender container assembly 22 by the user, which allows the user to move the blender container assembly 22 independent of the blender base 24. In the aspect shown in FIGS. 2 and 3, the handle 35 is coupled to the container 26 adjacent the second end 34 and extends substantially parallel to and spaced from the external surface 29 toward the first end 32. However, the handle 35 may be coupled to any suitable portion of the container 26.

[0029] The blender container assembly 22 may further include a spout 37. As shown in FIGS. 2 and 3, the spout 37 may be positioned along the opening 36 into the cavity 30 opposite the handle 35 and may extend outwardly at an angle from the internal surface 28 and beyond the external surface 29. The spout 37 is configured to direct and facilitate pouring of the foodstuff from the cavity 30 of the container 26 when the container 26 is tipped. It is to be appreciated that the spout 37 may be positioned at any suitable position along the container 26 that facilitates pouring of the foodstuff.

[0030] The container 26 may be tapered inwardly from the second end 34 to the first end 32 (e.g., from the top of the container 26 to the bottom of the container 26). The taper of the container 26 promotes movement of the foodstuff towards the second end 34 by guiding the foodstuff along the internal surface 28 of the container 26 during blending. The taper of the container 26 also promotes movement of the foodstuff towards the first end 32 after blending by facilitating movement along the internal surface 28 of the container 26. In some aspects the container 26 is formed a food safe polymer. Accordingly, the taper may function as a draft angle that allows for release of the container 26 from a mold used for production of the container (e.g., injection molding). It is to be appreciated that the container 26 may be formed by any production method that allows for production of the container 26. It is also to be appreciated that the container 26 may be formed from the any suitable food safe material that may contain foodstuff therein. It is also to be appreciated that the container 26 may have any suitable shape that allows for the storage and transport of foodstuff and removal of foodstuff from therein.VMX0318W0 / 131951 -777 PATENT

[0031] The blender container assembly 22 may further include a lid 38 that closes the opening 36 of the container 26 inhibit foodstuff from exiting the cavity 30 during operation of the blender system 20. The lid 38 may be selectively removed from engagement with the container 26 to allow the insertion of foodstuff into the cavity 30 of the container 26 through the opening 36. The lid 38 may further include one or more retention features 39 (e.g., locks, clips, interlocking components, mating components, recesses, protrusions, etc.) that engage the container 26 and prevent inadvertent removal of the lid 38 from the container 26. For example, the one or more retention features 39 may prevent the lid 38 from separating from the container 26 if the blender container assembly 22 is dropped or tipped, preventing and / or reducing the spillage of the foodstuff within the cavity 30 of the container 26. In another example, the one or more retention features 39 may prevent the lid 38 from being removed from the container 26 during a blending operation, preventing foodstuff from escaping the cavity 30 of the container 26 during the blending operation and also preventing outside items (including the appendages of the user) from entering the blending operation within the cavity 30. In the aspect shown in FIGS. 2 and 3, the one or more retention features 39 comprises two locks disposed on opposite sides of the container 26. However, any number of retention features 39 may be utilized.

[0032] The lid 38 may define an aperture 40 that opens into the cavity 30 of the container 26. As shown in FIG. 2, the aperture 40 may be smaller than the opening 36 of the container 26, which allows for additional foodstuff into the cavity 30 during operation of the blender without significantly inhibiting the closure of the container 26 with the lid 38. Therefore, the expulsion of foodstuff from the cavity 30 of the container 26 and entrance of outside items into the cavity 30 of the container 26 is reduced during the blending operation, while still allowing some access to the cavity 30 through the aperture 40. The aperture may be centrally located on the lid 38 such that foodstuff that travels from the first end 32 toward the second end 34 along the internal surface 28 of the container 26 and through the cavity along the axis A from the second end 34 toward the first end 32 during blending, preventing or minimizing foodstuff from splashing out of the container 26 through the aperture 40. The aperture 40 may also be used as an access point during insertion of blender tools (e.g., a tamper). The blender container assembly 22 may further include a plug 42 that selectively engages the lid 38 and closes the aperture 40. When closed, the plug 42 prevents access to the cavity 30 through aperture 40.VMX0318W0 / 131951 -777 PATENT

[0033] With reference to FIGS. 3-5, the blender container assembly 22 further includes a blade 44. The blade 44 is disposed within the cavity 30 and mounted to the container 26 at the first end 32. The blade 44 is rotatable relative to the container 26 about the axis A and is configured to be driven by the blender base 24 (e.g., engageable with components of the blender base 24, as described in greater detail below). The blade 44 includes a cutting portion 46 extending radially from the axis A and engages the foodstuff for performing the blending operation. The blade 44 further includes a shaft 48 coupled to the cutting portion 46. As shown in FIG. 6, blade 44 may further include a splined portion 50 coupled to the shaft 48, opposite the cutting portion 46. The splined portion 50 may engage the blender base 24 and receive the rotational motion of the blender base 24. The cutting portion 46 and the splined portion 50 are fixed to the shaft 48 such that the cutting portion 46, the shaft 48, and the splined portion 50 rotate together in unison. Rotation of the splined portion 50 by the blender base 24 is directly transmitted to the shaft 48 and the cutting portion 46.

[0034] The blade 44 may further include a guide 52 that engages both the shaft 48 and the container 26 and is configured to support and allow rotation of the shaft 48 relative to the container 26. In the aspect shown in the FIG. 6, the guide 52 includes a bearing for reducing friction between the shaft 48 and the container 26 as the shaft 48 rotates. Additionally or alternatively, the guide 52 may include a bushing or any other suitable component for supporting and allowing rotation of the shaft 48 relative to the container 26.

[0035] The blender container assembly 22 may further include a retainer nut 54 for securing the blade 44 with the container 26. The retainer nut 54 is disposed along axis A and on the external surface 29 of the container. The retainer nut 54 may have a threaded engagement with the guide 52. The retainer nut 54 engages the guide 52 and compresses the container 26 therebetween when tightened, securing the blade 44 with the container 26.

[0036] The blender container assembly 22 may further include a ring 56 mounted to the first end 32 of the container 26 around the shaft of the blade 44 and facing the blender base 24. The ring 56 may be configured for detection by the blender base 24 when the blender container assembly 22 is mounted thereto for identification of properties of the blender container assembly 22, such as the volume, shape, profile, etc. of the container 26. The identification of the blender container assembly 22 in-tum causes the blender base 24 to adjust various programs and parameters for use with the blender container assembly 22 that is mounted to the blender base 24 (e.g., ramp rate, blade rotation programs, max run time, etc.).VMX0318W0 / 131951 -777 PATENTIn one example, the ring 56 may include a coil that uses an inductive couple with wireless communication protocol such as near field communication (NFC) and may be referred to as an NFC ring. However, any suitable configuration of the ring 56 and corresponding communication protocol may be used.

[0037] As shown in FIG. 6, the sidewall 33 of the container 26 may have a thickness between the internal surface 28 and the external surface 29 that increases towards the container base 31. Said differently, the thickness of the sidewall 33 of the container 26 increases on progression from the second end 34 towards the first end 32. The increased thickness of the sidewall 33 of the container 26 adjacent the first end 32 strengthens the container 26 to be resistant to being dropped, in conjunction with the capacity of the container 26. More specifically, in the aspect shown in the Figures, the cavity 30 of the container 26 has a capacity of greater than or equal to one gallon. When filled with foodstuff, the capacity of the container 26 causes the overall weight of the container 26 to significantly increase. Often, the blender container assembly 22 is dropped in a substantially upright position, causing the first end 32 of the container 26 to be the first portion of the container 26 to contact a surface. The weight of the foodstuff due to the capacity of the container 26 can cause stress fractures at the first end 32 of the container 26 when the thickness of the container 26 is uniform. The increased thickness of the sidewall 33 of the container 26 towards the first end 32 strengthens the container 26 and reduces the propagation of stress fractures. It is to be appreciated that in other aspects, the container 26 may have a constant thickness.

[0038] Returning now to FIG. 4, the cutting portion 46 of the blade 44 includes arms 58 that extend radially from the axis A. In the aspect shown in FIG. 4, the cutting portion 46 uses four of the arms 58 equally spaced from one another about the axis A. However, any number of arms 58 may be used. Two of the arms 58 may be angled to extend in a first direction toward the second end 34 of the container 26 on progression from the axis A and two of the arms 58 may be angled to extend in a second direction toward the first end 32 of the container on progression from the axis A (see FIG. 2). However, the arms 58 may be arranged at any angle (individually or collectively) and may extend in any suitable direction.

[0039] With reference to FIG. 5, the blade 44 defines a blade diameter D measured radially and orthogonal to the axis A. More specifically, the blade diameter D refers to the maximum reach of the arms 58 of the blade 44 radially and orthogonally to the axis A. In the example shown in FIG. 5, the maximum reach of the arms 58 is defined by a distal end of atVMX0318W0 / 131951 -777 PATENT least one of the arms 58 (e.g., the distal extent of the arms 58 of the blade 44 defines the maximum reach and the blade diameter D).

[0040] The blade 44 is spaced from the internal surface 28 of the container 26 by a gap distance G measured radially and orthogonal to the axis A. In one aspect, a ratio of the blade diameter D to the gap distance G is from 1.0 to 2.75. In another aspect, a ratio of the blade diameter D to the gap distance G is from 1.46 to 2.14. As shown in FIG. 5, the internal surface 28 of the container 26 has a cross-sectional profile orthogonal to the axis A that is a rounded square. Therefore, the gap distance G varies about the axis A. In particular, the gap distance G is greater at the rounded corners of the square than between the rounded comers. Therefore, the ratio of the blade diameter D to the gap distance G may vary along the internal surface 28 of the container 26 in accordance with the ranges of the ratio as presented above.

[0041] As shown in FIG. 6, the cutting portion 46 of the blade 44 is spaced from the internal surface 28 along the axis A by a height distance H. More specifically, the height distance H refers to a surface of the cutting portion 46 of the blade 44 that is closest to the internal surface 28 in a direction extending parallel to the shaft 48 and the axis A. The height distance H represents a range in which the blade 44 sufficiently blends the foodstuff. In some aspects, the height distance H may be between 0.25 inch and 1 inch. In other aspects, the height distance H may be between 0.5 inch and 0.710 inch.

[0042] FIG. 7 schematically depicts another aspect of the blender system 20A. The blender system 20A is similar to the blender system 20 of FIGS. 1-6. As such, like reference numbers will be used to refer to like parts. The aspect of the blender system 20A in FIG. 7 differs from the aspect of the blender system 20 in FIGS. 1-6 in the configuration of the guide 52, which positions the blade 44 at a height distance H that is greater than the height distance H in the aspect in FIGS. 1-6, but still within range of the height distance H as discussed above with respect to FIGS. 1-6.

[0043] With reference to the aspects in FIGS. 6 and 7, the blender base 24 includes an electric motor 60 that, when energized, produces rotational motion that drives the blending of the foodstuff. The electric motor 60 may include a stator 62 positionally fixed within the blender base 24. The electric motor 60 may further include a rotor 64 and an output shaft 66 disposed within the blender base 24 and surrounded by the stator 62. The output shaft 66 and the shaft 48 of the blade 44 may be axially aligned and connected by a coupling 68. The electricVMX0318W0 / 131951 -777 PATENT motor 60 may further include a pair of bearings 70 that position the output shaft 66 within the blender base 24 and allow rotation of the output shaft 66 about the axis A. The rotor 64 may be fixed to and rotatable with the output shaft 66 about the axis A.

[0044] The stator 62 may include one or more electromagnets that produce a magnetic field. The rotor 64 may include a material that reacts with the magnetic force of the magnetic field. Accordingly, the magnetic field generated by the stator 62 may drive rotation of the rotor 64 and the output shaft 66 about the axis A. Because the output shaft 66 is connected to the shaft 48 of the blade 44 by the coupling 68, the shaft 48 of the blade 44 rotates in unison with the output shaft 66 of the electric motor 60. Therefore, the blade 44 is directly driven by the electric motor 60, without the use of a speed reduction component such as a gear box or a belt drive. The blender base 24 may have a speed profile of from about 1,400 revolutions per minute (RPM) to about 22,500 RPM, which is representative of a direct drive blender base without the use of a speed reduction mechanism.

[0045] The configuration of the blades 44 and the container 26 of the blender container assembly 22 facilitates the ability of the electric motor 60 to directly drive the blending of the foodstuff. More specifically, the ratio of the blade diameter D to the gap distance G as described above balances the load on the electric motor 60 with the quality of the blending operation. If the blade diameter D is increased (positioning the cutting portion 46 closer to the internal surface 28) and is outside of the ratio, the blade 44 sufficiently blends the foodstuff. However, the torque to rotate the blade 44 becomes larger and draws a higher current that can overheat the electric motor 60. On the other hand, if the blade diameter D is decreased (positioning the cutting portion 46 further from the internal surface 28) and is outside of the ratio, the torque to rotate the blade 44 is lower and does not overheat. However, the size of the blade 44 cannot sufficiently pull foodstuff down into the blade 44, causing an insufficient blend. The ratio of the blade diameter D to the gap distance G as described above was discovered unexpectedly over the course of much designing, testing, redesigning, etc. to achieve the objective of finding a specific ratio that would allow for large capacity containers to be used effectively with direct drive blender bases.

[0046] FIGS. 8 and 9 depict test data in support of the above-mentioned correlations. FIG. 8 is a graph of test data showing current draw of a blender base relative to a blade diameter of a blade for four different configurations of the blade, tested with three variations of foodstuff. The blade configurations progressively increase in blade diameter from Blade #1 through BladeVMX0318W0 / 131951 -777 PATENT#4. In the three tests, the current draw on the blender base increased with the blade diameter of the blade. FIG. 9 shows computational fluid dynamics plots for three variations of a blender system. The plot on the top depicts a blender system that uses a large blade with a speed reduction while the plot in the middle and the plot on the bottom depict blender systems with direct drive and a blade that is comparatively smaller than the blade used in the blender system in the plot on the left. The plots visualize the fluid velocity vectors for foodstuff tested with the systems. The plots show that a smaller blade diameter allows the electric motor directly driving the blades to rotate quicker than the larger blade with speed reduction. This results in large fluid velocities entering and exiting the blade, effectively pumping the foodstuff in a vortex type fluid field. The larger fluid velocities results in more processed blend, finer consistency, and less unprocessed large particles of the foodstuff.

[0047] In view of the test data shown in FIGS. 8-9, the following table can be derived that ascertains the acceptability of the tested blade for use with the direct drive blender base.Table 1VMX0318W0 / 131951 -777 PATENTVMX0318W0 / 131951 -777 PATENT

[0048] The blender container assembly 22 as described herein could be configured for use with a blender base having an indirect drive (e.g., with a speed reduction component such as a gear box). However, the ratio described herein causes the blade 44 to be smaller than other blades used in indirect drive systems with a speed reduction component in order to reduce the torque to rotate the blade 44. Therefore, if a blender base having an indirect drive were to be used with the blender container assembly 22 described herein, the size of the blade 44 combined with the slower speed of the indirect drive would produce an insufficient blend of the foodstuff.

[0049] From the above, it is to be appreciated that defined herein is a blender container assembly for use with a blender base having a direct drive includes a container having an internal surface defining a cavity and a blade disposed within the cavity and mounted to the container. The blade is rotatable relative to the container. The blade includes a shaft configuredVMX0318W0 / 131951 -777 PATENT to be directly driven by an electric motor of the blender base and a cutting portion extending radially from the shaft and defining a blade diameter. The cutting portion is spaced from the internal surface of the container by a gap distance. A ratio of the blade diameter to the gap distance is from 1.0 to 2.75.

[0050] The aspects of the blender container assembly described herein offer several advantages over other blender container assemblies. The configuration of the blade and the container as described herein direct the foodstuff away from the blade, upwardly along the internal surface, and back down toward the blade along the axis, forming a vortex that allows for uniform and complete blending of the foodstuff. Moreover, the configuration of the blade and the container allows for blending with the electric motor of the blender base, reducing heat production and the potential for thermal overload and damage to the electric motor and the electronics of the blender base.

[0051] Further aspects of the aspects described herein are provided by the subject matter of the following clauses:

[0052] A blender container assembly for use with a blender base having a direct drive, the blender container assembly comprising: a container having an internal surface defining a cavity; and a blade disposed within the cavity and mounted to the container, the blade rotatable relative to the container, the blade comprising: a shaft configured to be directly driven by an electric motor of the blender base; and a cutting portion extending radially from the shaft and defining a blade diameter, the cutting portion spaced from the internal surface of the container by a gap distance, wherein a ratio of the blade diameter to the gap distance is from 1.0 to 2.75.

[0053] The blender container assembly of any preceding clause, wherein the ratio of the blade diameter to the gap distance is from 1.46 to 2.14.

[0054] The blender container assembly of any preceding clause, wherein the ratio of the blade diameter to the gap distance varies along the internal surface of the container.

[0055] The blender container assembly of any preceding clause, wherein the cutting portion of the blade spaced from the internal surface by a height distance measured parallel to the shaft, wherein the height distance is from 0.25 inch to 1 inch.VMX0318W0 / 131951 -777 PATENT

[0056] The blender container assembly of any preceding clause, the height distance is from 0.5 inch to 0.710 inch.

[0057] The blender container assembly of any preceding clause, wherein the container extends along an axis between a first end configured to mount to the blender base and a second end configured to selectively receive foodstuff in the cavity.

[0058] The blender container assembly of any preceding clause, wherein the blade is rotatable relative to the container about the axis.

[0059] The blender container assembly of any preceding clause, wherein the blade diameter is measured radially and orthogonal to the axis, the blade spaced from the internal surface of the container by the gap distance measured radially and orthogonal to the axis.

[0060] The blender container assembly of any preceding clause, wherein the cutting portion comprises a plurality of arms, at least one of the arms angled to extend in a first direction toward the first end of the container and at least one of the arms angled to extend in a second direction toward the second end of the container.

[0061] The blender container assembly of any preceding clause, wherein the cavity of the container has a capacity of greater than or equal to one gallon.

[0062] The blender container assembly of any preceding clause, wherein the container has an external surface, opposite the internal surface, a sidewall of the container having a variable thickness between the internal surface and the external surface that increases towards a container base of the container.

[0063] The blender container assembly of any preceding clause, further comprising a retainer nut that couples with the shaft of the blade and compresses the container therebetween for securing the blade with the container.

[0064] The blender container assembly of any preceding clause, further comprising a near field communication (NFC) ring mounted to the container around the shaft of the blade.

[0065] The blender container assembly of any preceding clause, wherein the container extends along an axis, the internal surface is a sidewall of the container, and the gap distance is measured orthogonal to the axis from the distal extent of the blade to the sidewall.VMX0318W0 / 131951 -777 PATENT

[0066] A blender system comprising: a blender base having an electric motor; and a blender container assembly comprising: a container having an internal surface defining a cavity; and a blade disposed within the cavity and mounted to the container, the blade rotatable relative to the container, the blade comprising: a shaft directly driven by the electric motor of the blender base; and a cutting portion extending radially from the shaft and defining a blade diameter, the cutting portion spaced from the internal surface of the container by a gap distance, wherein a ratio of the blade diameter to the gap distance is from 1.0 to 2.75.

[0067] The blender system of any preceding clause, wherein the electric motor comprises: a stator; a rotor rotationally driven by the stator; and an output shaft fixed to and rotatable with the rotor, the output shaft rotationally fixed to the shaft of the blade to directly drive rotation of the blade.

[0068] The blender system of any preceding clause, wherein the output shaft of the electric motor and the shaft of the blade are axially aligned.

[0069] The blender system of any preceding clause, wherein the electric motor has a speed profile of from 1,400 revolutions per minute (RPM) to 22,500 RPM.

[0070] The blender system of any preceding clause, wherein the ratio of the blade diameter to the gap distance varies along the internal surface of the container.

[0071] The blender system of any preceding clause, wherein the cutting portion of the blade spaced from the internal surface by a height distance measured parallel to the shaft, wherein the height distance is from 0.25 inch to 1 inch.

[0072] A blender container assembly for use with a blender base having a direct drive, the blender container assembly comprising: a container having an internal surface defining a cavity; and a blade disposed within the cavity and mounted to the container, the blade rotatable relative to the container, the blade comprising: a shaft configured to be directly driven by an electric motor of the blender base; and a cutting portion extending radially from the shaft and defining a blade diameter, the cutting portion spaced from the internal surface of the container by a gap distance, wherein a ratio of the blade diameter to the gap distance is from 1.46 to 2.14 and varies along the internal surface of the container, the cutting portion of the blade spaced from the internal surface by a height distance measured parallel to the shaft, wherein the height distance is from 0.5 inch to 0.710 inch.VMX0318W0 / 131951 -777 PATENT

[0073] The blender container assembly of any preceding clause, wherein the container extends along an axis between a first end configured to mount to the blender base and a second end configured to selectively receive foodstuff in the cavity.

[0074] The blender container assembly of any preceding clause, wherein the blade is rotatable relative to the container about the axis.

[0075] The blender container assembly of any preceding clause, wherein the blade diameter is measured radially and orthogonal to the axis, the blade spaced from the internal surface of the container by the gap distance measured radially and orthogonal to the axis.

[0076] The blender container assembly of any preceding clause, wherein the cutting portion comprises a plurality of arms, at least one of the arms angled to extend in a first direction toward the first end of the container and at least one of the arms angled to extend in a second direction toward the second end of the container.

[0077] The blender container assembly of any preceding clause, wherein the cavity of the container has a capacity of greater than or equal to one gallon.

[0078] The blender container assembly of any preceding clause, wherein the container has an external surface, opposite the internal surface, a sidewall of the container having a variable thickness between the internal surface and the external surface that increases towards a container base of the container.

[0079] The blender container assembly of any preceding clause, further comprising a retainer nut that couples with the shaft of the blade and compresses the container therebetween for securing the blade with the container.

[0080] The blender container assembly of any preceding clause, further comprising a near field communication (NFC) ring mounted to the container around the shaft of the blade.

[0081] The blender container assembly of any preceding clause, wherein the container extends along an axis, the internal surface is a sidewall of the container, and the gap distance is measured orthogonal to the axis from the distal extent of the blade to the sidewall.

[0082] While particular aspects have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing fromVMX0318W0 / 131951 -777 PATENT the spirit and scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, such aspects need not be utilized in combination. It is therefore intended that the appended claims cover all such changes and modifications that are within the scope of the claimed subject matter.

Claims

VMX0318W0 / 131951 -777 PATENTWhat is claimed is:

1. A blender container assembly for use with a blender base having a direct drive, the blender container assembly comprising: a container having an internal surface defining a cavity; and a blade disposed within the cavity and mounted to the container, the blade rotatable relative to the container, the blade comprising: a shaft configured to be directly driven by an electric motor of the blender base; and a cutting portion extending radially from the shaft and defining a blade diameter, the cutting portion spaced from the internal surface of the container by a gap distance, wherein a ratio of the blade diameter to the gap distance is from 1.0 to 2.75.

2. The blender container assembly of claim 1, wherein the ratio of the blade diameter to the gap distance is from 1.46 to 2.14.

3. The blender container assembly of any one of claims 1-2, wherein the ratio of the blade diameter to the gap distance varies along the internal surface of the container.

4. The blender container assembly of any one of claims 1-3, wherein the cutting portion of the blade spaced from the internal surface by a height distance measured parallel to the shaft, wherein the height distance is from 0.25 inch to 1 inch.

5. The blender container assembly of claim 4, the height distance is from 0.5 inch to 0.710 inch.

6. The blender container assembly of any one of claims 1-5, wherein the container extends along an axis between a first end configured to mount to the blender base and a second end configured to selectively receive foodstuff in the cavity.

7. The blender container assembly of claim 6, wherein the blade is rotatable relative to the container about the axis.VMX0318W0 / 131951 -777 PATENT8. The blender container assembly of any one of claims 6-7, wherein the blade diameter is measured radially and orthogonal to the axis, the blade spaced from the internal surface of the container by the gap distance measured radially and orthogonal to the axis.

9. The blender container assembly of any one of claims 6-8, wherein the cutting portion comprises a plurality of arms, at least one of the arms angled to extend in a first direction toward the first end of the container and at least one of the arms angled to extend in a second direction toward the second end of the container.

10. The blender container assembly of any one of claims 1-9, wherein the cavity of the container has a capacity of greater than or equal to one gallon.

11. The blender container assembly of claim 10, wherein the container has an external surface, opposite the internal surface, a sidewall of the container having a variable thickness between the internal surface and the external surface that increases towards a container base of the container.

12. The blender container assembly of any one of claims 1-11, further comprising a retainer nut that couples with the shaft of the blade and compresses the container therebetween for securing the blade with the container.

13. The blender container assembly of any one of claims 1-13, further comprising a near field communication (NFC) ring mounted to the container around the shaft of the blade.

14. The blender container assembly of any one of claims 1-13, wherein the container extends along an axis, the internal surface is a sidewall of the container, and the gap distance is measured orthogonal to the axis from the distal extent of the blade to the sidewall.

15. A blender system, comprising: a blender base having an electric motor; and a blender container assembly comprising: a container having an internal surface defining a cavity; and a blade disposed within the cavity and mounted to the container, the blade rotatable relative to the container, the blade comprising:VMX0318W0 / 131951 -777 PATENT a shaft directly driven by the electric motor of the blender base; and a cutting portion extending radially from the shaft and defining a blade diameter, the cutting portion spaced from the internal surface of the container by a gap distance, wherein a ratio of the blade diameter to the gap distance is from 1.0 to 2.75.

16. The blender system of claim 15, wherein the electric motor comprises: a stator; a rotor rotationally driven by the stator; and an output shaft fixed to and rotatable with the rotor, the output shaft rotationally fixed to the shaft of the blade to directly drive rotation of the blade.

17. The blender system of claim 16, wherein the output shaft of the electric motor and the shaft of the blade are axially aligned.

18. The blender system of any one of claim 15-17, wherein the electric motor has a speed profile of from 1,400 revolutions per minute (RPM) to 22,500 RPM.

19. The blender system of any one of claims 15-18, wherein the ratio of the blade diameter to the gap distance varies along the internal surface of the container.

20. The blender system of any one of claims 15-19, wherein the cutting portion of the blade is spaced from the internal surface by a height distance measured parallel to the shaft, wherein the height distance is from 0.25 inch to 1 inch.

21. A blender container assembly for use with a blender base having a direct drive, the blender container assembly comprising: a container having an internal surface defining a cavity; and a blade disposed within the cavity and mounted to the container, the blade rotatable relative to the container, the blade comprising: a shaft configured to be directly driven by an electric motor of the blender base; and a cutting portion extending radially from the shaft and defining a blade diameter, the cutting portion spaced from the internal surface of the container by a gap distance, wherein a ratio of the blade diameter to the gap distance is from 1.46 to 2.14 and varies along the internalVMX0318W0 / 131951 -777 PATENT surface of the container, the cutting portion of the blade spaced from the internal surface by a height distance measured parallel to the shaft, wherein the height distance is from 0.5 inch to 0.710 inch.

22. The blender container assembly of claim 21, wherein the container extends along an axis between a first end configured to mount to the blender base and a second end configured to selectively receive foodstuff in the cavity.

23. The blender container assembly of claim 22, wherein the blade is rotatable relative to the container about the axis.

24. The blender container assembly of any one of claims 22-23, wherein the blade diameter is measured radially and orthogonal to the axis, the blade spaced from the internal surface of the container by the gap distance measured radially and orthogonal to the axis.

25. The blender container assembly of any one of claims 22-24, wherein the cutting portion comprises a plurality of arms, at least one of the arms angled to extend in a first direction toward the first end of the container and at least one of the arms angled to extend in a second direction toward the second end of the container.

26. The blender container assembly of any one of claims 21-25, wherein the cavity of the container has a capacity of greater than or equal to one gallon.

27. The blender container assembly of claim 26, wherein the container has an external surface, opposite the internal surface, a sidewall of the container having a variable thickness between the internal surface and the external surface that increases towards a container base of the container.

28. The blender container assembly of any one of claims 21-27, further comprising a retainer nut that couples with the shaft of the blade and compresses the container therebetween for securing the blade with the container.

29. The blender container assembly of any one of claims 21-28, further comprising a near field communication (NFC) ring mounted to the container around the shaft of the blade.VMX0318W0 / 131951 -777 PATENT30. The blender container assembly of any one of claims 21-29, wherein the container extends along an axis, the internal surface is a sidewall of the container, and the gap distance is measured orthogonal to the axis from the distal extent of the blade to the sidewall.

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