WO2007065219A1

WO2007065219A1 - Spin moulding apparatus

Info

Publication number: WO2007065219A1
Application number: PCT/AU2006/001859
Authority: WO
Inventors: Mark Armstrong; Henri Spaile
Original assignee: Idee Products Pty Ltd
Priority date: 2005-12-09
Filing date: 2006-12-09
Publication date: 2007-06-14

Abstract

An apparatus for producing a moulded confection, the apparatus comprising: a mould for retaining the confection therein; mould support means for retaining the mould, a mounting station for mounting the mould and drive means capable of imparting movement to the mould. Movement of the mould is responsive to drive imparted by the drive means and causes the confection to conform to the shape of an inside contour of the mould.

Description

SPIN MOULDING APPARATUS BACKGROUND

The present invention relates to appliances and apparatuses and more particularly relates to apparatuses for moulding confectionary products. The invention further relates to an appliance for moulding of chocolate products and a method thereof. The invention further relates to a method of manufacture of such chocolate products using rotational moulding.

PRIORART

There are in existence a number of apparatus used in the manufacture of confections and more particularly those which are moulded into predetermined shapes. There are also apparatuses for mass production of chocolate products shaped by moulds or presses. By way of an example of the prior art, United States Patent 6,772,679 teaches an Apparatus for making chocolate articles on a conveyor web An embodiment of the invention includes an apparatus for making edible articles but of a chocolate mass that is tempered and deposited directly on a conveyor web The apparatus includes a holding a holding and cooling device carrying plungers with pressing surfaces arranged above the conveyor web. The plungers with pressing surfaces are configured to be moved up and down relative to the conveyor web. The holding device with plungers as well as an underlying part of the conveyor web is arranged in a housing connected to an air dryer adapted to supply dry air into the housing.

United States Patent 6,268,006 teaches a method for producing consumable items the invention relates to a method for the production of consumable items having an outer jacket made from a flowable mass, which is filled in a mold. A tempered die is immersed into the mold and the mass is extruded. United States Patent 6,543,248 teaches an apparatus for molding frozen confectionery compositions into articles The device for moulding frozen confectionery articles comprises a metering hopper connected to a volumetric metering device comprising a metering chamber and a metering element dispensing a predetermined volume of ice cream into passing containers by means of a metering nozzle. m a further example of manufacture of moulded confections, United States Patent 4,822,268 discloses a conveying and treatment apparatus for moulds fiUable with a castable, solidifying body, such as chocolate mass. The invention relates to a conveying and treatment apparatus for double moulds for making hollow bodies of a castable, solidifying substance, such as chocolate mass. The double moulds consist of two plate-shaped mould halves which have corresponding mould cavities and are laid one above the other to close the cavities. The apparatus comprises a conveying path via which the double moulds filled with the mass can be fed to a transfer device which takes over the double moulds after the fashion of continuous lift and supplies the moulds to an endless conveyor. During conveying in the transfer device, the double moulds are conveyed in parallel and synchronously with supporting and retaining elements of the endless conveyor, being transferred in synchronism by means of a pushing device from the transfer device to the chain conveyor. During conveying in the endless conveyor the double moulds are held together and at the same time rotated around their own axes, more particularly around two axes, so that the castable body gradually solidifies by cooling on the walls of the mould cavities.

United States Patent 4,068,993 discloses a confectionery moulding machine comprising an endless mould conveyor which traverses moulds in continuous procession in an upper run in which the cavities in the moulds face upwardly and in a lower run in which the mould cavities face downwardly, a depositor for depositing liquid confectionery into the moulds in succession as they travel along the upper run, a conveyor band which travels continuously beneath the lower run of the mould conveyor, and a demoulding unit for discharging the fillings of the cavities of each mould in succession onto the conveyor band.

United States Patent 5,135,767 discloses a process and apparatus for the production of an article of ice confectionery To make an article of ice confectionery having a flaky texture, superposed ribbons of ice confectionery and a crispy composition are extruded into a mold in the form of a body of revolution by means of an extrusion assembly comprising a flat extrusion tube and a spray tube. The support of the extrusion assembly receives a spinning movement resulting from a continuous horizontal rotational movement and an ascending and descending movement relative to the mold. The processes and apparatuses described in the above US patents are intended for industrial applications. Although there are processes and apparatuses described for the purpose of moulding chocolates requiring two part moulds and in the case of US patent 4,822,268, spinning about axes, the prior art does not teach a domestic appliance or apparatus for small scale manufacture of confections such as moulded chocolates .

INVENTION

The present invention according to one aspect, provides an apparatus for moulding confectionary products. The invention according to a further aspect, provides a method of manufacture of a molded confection. The invention further provides a method of manufacture of such confectionary products using rotational or spin moulding wherein the mould is capable of rotation about at least one axis to centrifuge a liquid confection against a wall of a mould. . One object of the present invention is to provide an apparatus which allows domestic relatively small scale production of confectionary products in a potentially unlimited variety of shapes. A further object of the invention is to provide a method of mass production of confections which allows domestic production of confectionary products in a potentially unlimited variety of shapes.

Additional objects of the present invention will appear as the description proceeds.

In its broadest form the present invention comprises:

an apparatus for producing a moulded confection, the apparatus comprising: a mould for retaining the confection therein;

mould support means for retaining the mould,

drive means capable of imparting movement to the mould, wherein, movement of the mould responsive to said drive imparted by said drive means causes the confection to conform to the shape of an inside contour of the mould.

Ih another broad form the present invention comprises:

an apparatus for producing a moulded confection, the apparatus comprising: a mould for retaining the confection;

a mounting station for mounting the mould;

drive means capable of imparting movement to the mould, wherein, movement of the mould causes the confection to conform to the shape of an inside contour of the mould.

According to one embodiment the apparatus further comprises a housing which accommodates the mould station, the mould and the drive means.

Preferably the drive means is at least one electric motor which in operation causes the moulding to rotate on an axis as a spin mould. Preferably the confection is a solid at room temperature for insertion in the mould and is heated by a heater in the housing to a flowable liquid state such that when the mould spins the confection confirmed by centrifugal action of the walls of the mould thereby confirming to

According to a preferred embodiment the mould is formed from opposing mould parts. According to one embodiment the confection is chocolate.

In another broad form of a method aspect the present invention comprises: a method of production of a confection in an apparatus comprising:

a mould for retaining the confection;

a mounting station for mounting the mould;

drive means capable of imparting movement to the mould,

the method comprising the steps of :

a) introducing a sold confection into a cavity in said mould formed by mould parts;

b) closing mould parts to form a closed cavity in which the confection is held; c) heating the confection to a flowable consistency;

d) activating said drive means to spin said mould;

e) spinning the mould to an extent which causes the flowable confection to conform to the shape of an inside contour of the mould.

The mould may be adapted with a potentially unlimited number of shapes and is well suited to the moulding of chocolate products.

Materials which may be selected for the mould include polypropylene or other suitable plastics material. . The present invention provides an alternative to the known prior art and the shortcomings identified. The foregoing and other objects and advantages will appear from the description to follow. In the description reference is made to the accompanying drawing, which forms a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying illustrations, like reference characters designate the same or similar parts throughout the several views.

The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims.

BRIEF DESCRIPTION OF DRAWINGS Figure 1 shows a front view of a rotational molding apparatus according to one embodiment .

Figure 2 shows a front view of the rotational molding apparatus of figure 1 with access door removed.

Figure 3 shows a left side elevation view of the rotational molding

apparatus of figure 1.

Figure 4 shows a right side elevational view of the rotational molding

apparatus of figure

Figure 5 shows a top view of the rotational molding apparatus of figure 1. Figure 6 shows a bottom view of the rotational moulding apparatus of figure

1.

Figure 7 shows a rear elevation view of the rotational rotational molding apparatus of figure 1.

Figure 8a shows a front elevation view of the rotational mold divided by section line A-A.

Figure 8b shows a longitudinal sectional view of the rotational moulding apparatus of figure 8a.

Figure 9a shows a side elevation view of the rotational mold divided by section line B-B.

Figure 9b shows a longitudinal sectional view of the rotational moulding apparatus of figure 9a. Figure 10 shows a right side view of the rotational moulding assembly with protective housing removed.

Figure 11 shows a rear view of the exposed moulding assembly of figure 10 with housing removed.

DETAILED DESCRIPTION

Referring to figure 1 there is shown a front view of a rotational molding apparatus 1 according to a preferred embodiment. Apparatus 1 comprises a primary housing 2 having a wall 3 defining an internal cavity 4. Wall 3 is partially abbreviated to form a recess which allows access to cavity 4 via a door 5 supported by door hinges 6 and 7. Door 5 may be totally removed or undergo rotational hinged removal. Housing 2 further comprises a series of indicating lights S, 9, 10 and 11. These are preferably LED's coloured to indicate phases of operation or energisation of apparatus 1. For instance, LED 8 may be used to indicated a heating cycle, LED 9 to indicate a power on state, LED 10 to indicate a cooling cycle and LED 11 to indicate a ready state. Housing 2 includes a flat base 12 which allows apparatus 1 to be free standing and stable in use.

Figure 2 shows a front view of the rotational molding apparatus of figure 1 with access door 5 removed. Removal of access door 5 exposes cavity 4 which receives and retains therein a two piece mould 13, assembled from mould parts 14 and 15. Mould 13 houses a confection material 7 which is eventually formed into a confection of a predetermined shape which conforms to an inner shape of mould 13. Preferably mould 13 is manufactured from clear PET which allows an operator to visually inspect the spin moulding process during operation as apparatus 1. Figure 2 also shows in cavity 4 air vents 16 which allow circulation of air through the cavity 4 for airing and particularly cooling during operation. Mould 13 is mounted on a mould support 17 which is preferably retained at lower end 18 and upper end 19. Upper end 19 of support 17 engages vibration motor 20 which transmits a vibration through mould 13 to enhance distribution of the confection when in the liquid state in the mould.

Figure 3 shows a left side elevation view of the rotational molding apparatus of figure 1 with corresponding numbering for corresponding parts. Housing 2 further includes an isolation switch 21 which isolates power to the apparatus. An opening 22 is provided to allow access to power cable 23. Housing 2 further comprises rear air vents 24 which allow air circulation for cooling purposes.

Figure 4 shows a right side elevational view of the rotational molding apparatus 1 with corresponding numbering. Figure 5 shows a top view of the rotational molding apparatus 1 with corresponding numbering. Housing 2 includes a cycle start and stop button 25 which is operable once apparatus has power. Figure 6 shows a bottom view of the rotational moulding apparatus of figure 1 with corresponding numbering and figure 7 shows a rear elevation view of the rotational molding apparatus of figure 1. Figure 8a shows a front elevation view of the rotational mold apparatus 1 divided by section line A-A. Figure 8b shows a longitudinal sectional view of the rotational moulding apparatus 1 of figure Sa. From figure Sb internal components of assembly 1 are visible. Mould 13 in use is rotated about a Y ( vertical) axis and simultaneously about a Z (horizontal ) axis. Rotational drive is imparted by motor.26 which transmits drive through drive axle 27 to cowl 28. Located near motor 26 is fan 29 which expels heated air via air vents 24. Located near cowl 28 is a heating element 30 which heats a confection contained in mould 13 to increase flowability thereby enhancing moulding as mould 13 rotates. In the case of use of chocolate chips, these are introduced into the mould in a solid state. Upon activation of the heater, the chips melt but must be evenly or at least as evenly as possible over the inner surface of mould 13. Chamber 31 houses mould 13 and mould holder 17. Holder 17 engages support 32 which is activated by bevel gear 33 establishing the rotation of mould holder 17 and therefore mould 13 about the Y axis. At its opposite end 19, holder 17 engages vibration motor 20. Magnets may be used to accurately align and maintain desired attitude of holder 17. Vibration motor 20 oscillates and facilitates a more even distribution of molten chocolate over the mould surface. Gravity and relatively slow revolutions per minute contribute to the even distribution of the liquid confection throughout the surface of the mould. In operation, motor 26 imparts Z axis rotation to chamber. This translates into Y rotation by rotation of beville gear 33 which rotates responsive to rotation of chamber 31. Located near motor 26 is fan 29 which expels heated air via air vents 24.

Figure 9a shows a side elevation view of the rotational mold apparatus 1 divided by section line B-B. Figure 9b shows a longitudinal sectional view of the rotational moulding apparatus 1 looking into cavity 4. Rotational drive is imparted by motor 26 which transmits drive to cowl 28. Cowl 28 rotates, relative to stationary circular rack 34 which includes a teeth array 35 which engages a gear assembly 36, Gear assembly 36 comprises a pair of co operating gear wheels 33 and 37 . Stationary rack 34 is engaged as cowl 28 rotates by gear wheel 37 which co operates with and imparts drive to gear wheel 33. Gear wheel 33 includes axle 32 which receives and retains thereon mould holder 17.

Figure 10 shows a right side view of the rotational moulding assembly 1 with protective housing 2 removed to expose the inner working components. As described rotational drive is imparted by motor 26 which transmits drive through drive axle 27 to cowl 28. Located near motor 26 is fan 29 which expels heated air. Holder 17 engages support 32 which is activated by bevel gear 33 establishing the rotation of mould holder 17 and therefore mould 13 about the Y axis. At is opposite end 19, holder 17 engages vibration motor 20.

In operation, motor 26 imparts Z axis rotation to chamber 31. This translates into Y axis rotation of holder 17 by rotation of beville gear wheel 33. Stationary rack 34 is engaged by gear wheel 37 as cowl 28 rotates and which co operates with and imparts drive to beville gear wheel 33. Gear wheel 33 includes axle 32 ( see figure 9b) which receives and retains thereon mould holder 17. Apparatus 1 further comprises a control PCB 40 which includes a programmable chip which controls operation cycles which are each timed. Cycles include heating, cooling, clockwise and counter clockwise rotation of the mould about at least two axes. Rotation about axes Y and Z is preferably simultaneous. Figure 11 shows a rear view of the exposed moulding apparatus 1 of figure 10 with housing removed to expose working components and with corresponding numbering.

Housing 2 may comprise ground engaging feet ( not shown) which support apparatus 1 and provide stability during rotation of the mould 13. Feet would preferably be disposed at 120 degrees.

Although the preferred shape formed by the mould is egg shaped or generally ovoid, it will be appreciated that mould 13 may be formed by a variety of shapes dictated by the shape of the final confection product required.

A chocolate confection formed by mould 13 will be three dimensionally ovoid. A potentially unlimited number of different shapes are possible such as but not limited to animals, shapes, eggs such as easter eggs, and other figures.

Advantages of the apparatus described herein include:

a) consumers can manufacture confections and particularly chocolate products such as easter eggs domestically.

b) the cost of chocolate confectionary is reduced.

d) the confection can be made expeditiously

e) consumers no longer need to shop for easter eggs. f) mould may be interchanged to produce difference shapes; g) the apparatus may be configured as a toy

According to one embodiment of a method aspect, a sample confection such as an easter egg chocolate would be made according to the following steps:

1. A consumer opens a packet of solid chocolate chips (and any other ingredients for the egg) and places these into Mould 13. For this step Mould 13 will be separated ( undipped) into its two parts 14 and 15 ( see figure 2) and when the chips have been inserted, the mold parts are reassembled.

2. The consumer fills one half of the mold with the chocolate chips and any other ingredients. The mould parts 14 and 15 are clipped together ensuring that both halves are properly mated together.

3. The user then inserts mold 13 into apparatus 1 via opening 4 and mounts it on mould holder 17 . Once door 5 is closed and power is on, the user presses the 'START' button 25. 4. This activates drive motor 26 which rotates mould 13.

5 Mould 13 is adapted for rotation in two directions or about two axes either concurrently or sequentially. 6 The mould is heated to liquefy the sold chocolate.

7 After 5 minutes of heating, the heating element is switched off and a cooling cycle begins. The mold continues to rotate during cooling to ensure that an even wall thickness of the chocolate is maintained. 8 After about 8 minutes of cooling, apparatus 1 emits an alarm or beeps and displays 'Remove' light. The cooling and rotation continues until the door 5 is opened.

9 The consumer removes mold 13 from apparatus 1 and places the mold in a

freezer for about 7 minutes. Apparatus 1 includes a built in timer, and after 7 minutes an alarm or beep is emitted and displays a ('Ready' ) light.

10 If the customer has not removed the final confections from apparatus 1 , then after an additional 15 minutes of cooling time the apparatus 1 beeps and turns off. 11 The customer unclips the mold from the apparatus and reveals the finished

hollow confection.

Technical Specifications are variable but according to a preferred embodiment apparatus 1 will have preferred but non limiting dimensions as follows:

Height: 265mm

Width: 180mm

Length: 225mm

Power requirements would according to a preferred embodiment be:

830W

220-240V

AC (50/60Hz)

A typical motor may be a Chiaphua Components Ltd (CCL) Model: SR-16 having the following electrical and mechanical parameters:

Type: Shaded Pole Single Phase Induction

Input Power: 26W

Output Power: 3.8W

Input Voltage: 100-240V AC 50/60Hz

Rated Speed: 3400RPM(max)

A preferred heating element is a Coiled Nichrome with Input Power: 800W. A preferred fan has parameters:

Type: Axial

Diameter: 110mm

Fan Speed: 2000RPM Mold Rotation Speed is preferably :

Major Axis: 5RPM

Minor Axis: 14RPM

Gear Reduction:

Type: 2 Stage worm gear

Ratio: 400:1

Both Stages 20:1

4mm Pitch

Single start worm

According to a preferred embodiment the Chocolate mould Capacity is as follows:

Max length: 130mm (5")

Max width: 115mm (4.5")

Max weight: lOOg

Estimated Cycle times with refrigeration

Heat: 5 min

Cool: 8 min

Freezer: 7 min

Total cycle time: 20min

Without refrigeration

Heat: 5 min

Cool: 23 min

Total cycle time: 28min It will be recognised by persons skilled in the art that numerous variations and modifications may be made to the invention broadly described herein without departing from the overall spirit and scope of the invention.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS: 1 An apparatus for producing a moulded confection, the apparatus comprising:

a mould for retaining the confection therein;

mould support means for retaining the mould,

2 An apparatus according to claim 1 wherein the drive means imparts rotational movement to said mould.

3 An apparatus according to claim 2 wherein the mould support retains the mould via at least one connection

4 An apparatus according to claim 3 wherein the mould is supported at opposite ends.

5 An apparatus according to claim 4 wherein the mould is capable of rotation responsive to said drive means about at least one axis.

6 An apparatus according to claim 5 wherein the mould is capable of rotation about a first axis and about a second axis normal to the first axis.

7 An apparatus according to claim 6 wherein the first axis is a Y axis and the second axis is a Z axis. 8 An apparatus according to claim 7 wherein said Y and Z axis rotations occur simultaneously.

9 An apparatus according to claim 8 wherein the drive means includes at least one electric motor .

10 An apparatus according to claim 9 wherein the electric motor drives a mould chamber which retains the mould support.

11 An apparatus according to claim 10 wherein, the mould chamber rotates in response to the action of said motor.

12 An apparatus according to claim 11 further comprising a gear assembly which allows rotation of the mould support about an axis normal to the axis of rotation of said chamber.

13 An apparatus according to claim 12 wherein the gear assembly comprises first and second co operating beville gears.

14 An apparatus according to claim 13 wherein the first of said gears is a wheel which engages a stationary rack having a teeth array which engages a corresponding teeth array of said first gear wheel.

15 An apparatus according to claim 14 wherein rotation of the mould chamber causes the first gear wheel to rotate as it engages the teeth array on the stationary rack.

16 An apparatus according to claim 15 wherein a second gear wheel co operates with said first gear wheel to impart rotation to said second gear wheel. 17 An apparatus according to claim 16 wherein an axle on the second gear wheel engages the mould holder thereby causing rotation of said mould holder.

18 An apparatus according to claim 17 wherein the mould is spin mould. 19 An apparatus according to claim 18 further comprising means to elevate the temperature of the confection so that the confection is changed from a solid to a fiowable consistency. 20 An apparatus according to claim 19 wherein said means to elevate the temperature of the confection is a heater.

21 An apparatus according to claim 20 further comprising a housing which accommodates the mould and mould support and drive motor.

22 An apparatus according to claim 21 wherein, the mould is formed from opposing mould parts.

23 An apparatus according to claim 22 wherein the opposing mould parts together form a wall defining a hollow interior.

24 An apparatus according to claim 23 wherein, the confection has a consistency which allows the confection to flow in response to said drive against at least one wall of the mould.

25 An apparatus according to claim 24 wherein when the mould spins, the confection is urged by rotation and gravity to conform to an internal surface shape of an inner surface of the mould 26 An apparatus according to claim 25 wherein the mould is manufactured from materials selected from PET, polypropylene or other suitable plastics material.

27 An apparatus according to claim 26 wherein the confection is introduced into the mould as a solid at room temperature and heated to a fiowable liquid by said heater. 28 An apparatus according to claim 27 wherein the moulded confection is chocolate.

29 An apparatus according to claim 28 wherein, the mould is contoured to form a variety of shapes.

30 An apparatus according to claim 29 wherein the mould produces hollow chocolates

31 An apparatus according to claim 30 wherein the hollow chocolates are easter eggs.

32 An apparatus according to claims 6 or 31 wherein its height fells within the range of 200 - 300mm, the width falls within the range of 100 -

200mm and the length falls within the range of 150 - 300mm.

33 An apparatus according to claim 32 wherein the drive motor is a shaded pole single phase induction having the following power requirements:

830W

220-240V

AC (50/60Hz) 34 An apparatus according to claim 33 wherein the motor has the following electrical and mechanical parameters:

Input Power: 26W

Output Power: 3.8W

Input Voltage: 100-240V AC 50/60Hz

Rated Speed: 3400RPM (max)

35 An apparatus according to claim 34 wherein the heater includes a heating element comprising a Coiled Nichrome with Input Power: 800W.

36 An apparatus according to claim 35 wherein a cooling fan has the following parameters:

Type: Axial

Diameter: 110mm

Fan Speed: 2000RPM

37 An apparatus according to claim 36 wherein the mold has a rotation speed about a major axis of 5RPM and about a minor axis 14RPM. 38 An apparatus according to claim 37 further comprising a worm gear assembly having a two stage gear reduction:

39 An apparatus according to claim 38 wherein the mould has an internal void with dimensions within the range length: 100 -130mm

width: 90 - 115mm

weight: 50 - 20Og

40 A method of production of a confection in an apparatus comprising: a mould for retaining the confection;

drive means capable of imparting movement to the mould,

the method comprising the steps of :

d) activating said drive means to spin said mould;

41 A method according to claim 40 wherein the mould spins concurrently about axes normal to each other.

42 A method according to claim 41 comprising a further step of switching off a heating element to begin a cooling cycle.

43 An apparatus according to claim 6 further comprising a PCB which controls apparatus cycle operation.

44 An apparatus according to claim 43 wherein the PCB comprises an intelligent module which controls said cycle operations.

45 An apparatus according to claim 43, further comprising LED displays to indicate an operation status of the apparatus.