US008679561B2

( 12) Ulllted States Patent ( 10) Patent N 0. : US 8, 679, 561 B2

Ludwig ( 4 5) Date o f Patent: Mar. 25, 2014
( 54 ) SMOKELESS COFFEE ROASTER 4 , 4 84 , 064 A * 11/1984 Murray . . . . . . . . . . . . . . . . . . . . . . . . . 219/4 00
5, 107, 776 A 4 /1992 G arc ia- Mallo l
_ . 5, 230, 281 A 7/1993 Wireman et a1.
L A * _ 5, 394 , 623 A 3/1995 SeWell
( 73) Ass1gnee: Lo ring Smart Ro ast, I nc . , Santa Ro sa, 5, 4 27, 74 6 A 6/ 1995 Pereira er a1,
CA ( Us) 5, 709, 54 2 A * l/l998 RentZel et al. . . . 4 31/24 2
5, 94 4 , 512 A * 8/1999 Ludwig . . . . . . . . . . . . . . . 4 32/72
- _ - - - - 5, 958, 4 94 A * 9/1999 Tidland et al. . . 4 26/4 66
( * ) N o t1c e. Sub j ec tto any d1sc la1mer, th e term o f th 1s 6, 260, 4 79 B1 * 70001 Friedric h et a1 99/4 68
Pawnt 1S mended Or a( b usted under 35 6, 607, 768 B1 * 8/2003 Eic h ner . . . . . . . . . . 4 26/4 66
U. S. C. 154 ( b ) b y 0 days. 7, 14 3, 686 B1* 12/2006 Sando lo . . . . . . . . . . . . . . . . . . . . . . . . . . 99/286
* . .
( 21) Ap p l. N O. Z 13/529, 838 ted b y exammer
_ 1 d_ Primary Examiner * Drew Bec ker
( 22) F1 e ' Jun21 2012 Assistant Examiner * Presto n Smith
( 65) Prio r Pub lic atio n Data ( 74 ) Atto rney, Agent, o r Firm 4 Th o mas M. Frelb urger
US 2013/034 4 207 A1 Dec . 26, 2013 ( 57) ABSTRACT
A c o f f ee b ean ro asting mac h ine o f th e typ e h av ing a c yc lo ne
( 51) I ntCl sep arato r h eating c h amb er and a c o f f ee b ean ro asting c h am
A23F 5/ 04 ( 2006- 01) b er in a rec irc ulating p ro c ess stream driv en b y a rec irc ulatio n
( 52) U- S- Cl- f an is o p erated to air c o o l th e ro asted c o f f ee b eans in th e
USPC - - - - - - - - - - ~ 4 26/4 66; 4 26/4 67; 4 26/233; 4 26/520; ro asting c h amb er, to a temp erature b eneath Wh ic h th e b eans
4 26/523; 4 26/4 86 giv e o f f smo ke, Wh ile at th e same time inc inerating smo ke
( 58) Field o f Classi? c atio n Searc h remo v ed f ro m th e ro asting c h amb er. A p urge gate in duc ting
USPC . . . . . . . . . . . . . . . . . 4 26/233, 4 67, 4 66, 520, 523, 4 86; b etWeen th e c yc lo ne sep arato r and th e ro asting c h amb er is
99/355, 357, 286; 34 /54 4 , 576, 393 o p ened to allo W th e Ho w o f amb ient air into and th ro ugh th e
See ap p lic atio n ? le f o r c o mp lete searc h h isto ry. ro asting c h amb er Wh ile b lo c king ? o W o ut o f th e c yc lo ne
sep arato r, so th at amb ient air is direc ted th ro ugh th e ro asting
( 56) Ref erenc es Cited c h amb er. Th e smo ke and any airb o rne p artic ulate material
U. S. PATEN T DOCUMEN TS
2, 212, 120 A 8/194 0 Kneale et a1.
3, 189, 4 60 A 6/1965 Smith , Jr.
3, 84 8, 550 A 11/1974 Bo wen
3, 855, 951 A 12/1974 G iles
f ro m th e ro asting c h amb er are c arried into th e h eating c h am
b er and th ro ugh th e inc ineratio n tub e, Wh ere th ey are inc in
erated. Pref erab ly th e system and p ro c ess are o p erated auto
matic ally b y a c o mp uter and p ro gramming.
5 Claims, 6 Drawing Sh eets
ROASTI
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CON TROLLER
EXHAUST
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CON TROLLER
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COMBUSTI BLE
MI XTURE
US. Patent Mar. 25, 2014 Sh eet 1 o f 6 US 8, 679, 561 B2
US. Patent Mar. 25, 2014 Sh eet 2 o f 6 US 8, 679, 561 B2
FI G . 2
US. Patent Mar. 25, 2014 Sh eet 3 o f 6 US 8, 679, 561 B2
52 4 6 4 8
CON TROLLER
COMBUSTI BLE
MI XTURE
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EXHAUST
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PROCESS
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ROASTI N G
CHAMBER
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CON TROLLER
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FI G . 3
US. Patent Mar. 25, 2014 Sh eet 4 o f 6 US 8, 679, 561 B2
EXHAUST
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22 52
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55%88 ' 1 34
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ROASTI N G
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CON TROLLER /
CON TROLLER
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COMBUSTI BLE
MI XTURE
US. Patent Mar. 25, 2014 Sh eet 5 o f 6 US 8, 679, 561 B2
US. Patent Mar. 25, 2014 Sh eet 6 0f 6 US 8, 679, 561 B2
lr
Po wer o n / 80 Air c o o l c yc le b egins /102
+
Beansii' 1 h o p p er /82 I nc rease b urner setting f 106
- - 106
Press b urnerstart /_ 84 I nc rease c irc . f an setting /
( idle mo de) 3 sec . 110
l, Op en p urge gate /'
Purge gate o p en I i
Circ . f an o n /86 " Air c o o l " o f b eans 10 sec . /112
20 Sec o nds to 60 see, as set
- +
Cic . f an lo wer / 88 l
i, Op en ro ast c h amb er
Purge gate c lo sed f go do o r to release b eans 116
- /
+ p anally c o o led, to
Burner ligh ts. Allo w 92 tray ( manual o r auto )
ro aster warm- up / l I 118
p erio d Po st ro ast mo de b egins /
Beans rnto ro ast / 94 Circ . f an to o wer setting f 120
c h amb er i 20 86C- 122
+ Clo se p urge gate /
Ro ast mo de/ l'
Ro ast f o r p resc rib ed / 96 Burner do wn to lo w f ire /124
duratio n, p resc rib ed l' .
b urner & c irc . f an settings, Po st ro ast mq de c o nl' nues /126
c o ntro lled b y o p erato r f o r p reset tlme p erio d
o r selec ted auto mo de
l,
End ro ast / 98
100 104
airc o o s? c c l POSJt
9 y ro ast
Y es
F | G . 6 N ew ro ast c yc le
US 8, 679, 561 B2
1
SMOKELESS COFFEE ROASTER
BACKG ROUN D OF THE I N VEN TI ON
Th is inv entio n p rimarily c o nc erns c o f f ee b ean ro asting,
alth o ugh th e inv entio n c an b e ap p lied to o th er ro asting o r
h eating ap p lic atio ns as Well.
Th e inv entio n is direc ted to imp ro v ements o n th e c o f f ee
b ean ro asting ap p aratus and meth o d desc rib ed in US. Pat.
N o . 5, 94 4 , 512, o Wned b y th e same assignee as th is inv entio n.
US. Pat. N o . 5, 94 4 , 512 is h ereb y inc o rp o rated b y ref erenc e
in its entirety.
I n th e ap p aratus o f US. Pat. N o . 5, 94 4 , 512, Wh ic h Was
ap p lic ab le to b ut no t sp ec i? c to c o f f ee b eans, c o f f ee b eans o r
o th er p ro duc ts Were ro asted in a c h amb er c o nnec ted in a
rec irc ulating p ro c ess stream lo o p With a c yc lo ne sep arato r
Wh ic h inc luded a h eating c h amb er. Th e p atented mac h ine h ad
a gas ? ame o r o th er h eat so urc e emanating f ro m th e b o tto m o f
th e h eating c h amb er and direc ted c o nc entric ally to Ward an
inc ineratio n tub e direc tly ab o v e. Th e p ro c ess stream Was
intro duc ed tangentially to th e c yc lo ne sep arato r, v ia a c irc u
lating f an o r b lo Wer With in th e p ro c ess stream, and sp iraled
do Wn to th e lo Wer regio n o f th e h eating c h amb er, aro und th e
h eating ? ame, th en b ac k up Wardly inside a c ylindric al sh ro ud
and j ust o utside th e inc ineratio n tub e, th en direc ted o ut o f th e
c yc lo ne sep arato r and duc ted b ac k to th e b ean ro asting c h am
b er. By th is design v ery little o f th e p ro c ess stream
c o - mingled With th e p ro duc ts o f c o mb ustio n f ro m th e h eat
so urc e, and th e p ro c ess stream Was h eated to an ef f ec tiv e
temp erature to ro ast th e b eans. I n th e c yc lo ne sep arato r, th e
c h af f f ro m th e c o f f ee b eans Was sep arated b y c entrif ugal
f o rc e, and settled do Wn to a p artic le c o llec tio n b in o r h o p p er.
I n th e c o f f ee b ean ro asters c o rresp o nding to US. Pat. N o .
5, 94 4 , 512 and so ld b y th e assignee o f th e p resent inv entio n,
af ter a ro ast Was c o mp leted th e b eans Were released f ro m th e
ro asting c h amb er into a c o o ler, f o r c o o ling o f th e b eans With
amb ient air draWn th ro ugh th e b eans b y a c irc ulating b lo Wer.
Smo ke Was released f ro m th e ro asted b eans into th e amb ient
air, until th e b eans Were c o o led to a suf ? c ient extent.
Also in th e p rio r c o f f ee b ean ro aster, a p urge f eature Was
inc luded Wh ereb y, b ef o re th e mac h ines h eat so urc e c o uld b e
ac tiv ated, saf ety c o nc erns and regulatio ns req uired th at th e
entire system v o lume ( atmo sp h ere) b e rep lac ed b y a v o lume
o f f resh air no t less th an ? v e times th e system v o lume, to
p rev ent th e p o ssib ility o f ignitio n and exp lo sio n. A p urge gate
Was inc luded in a duc t in th e p ro c ess stream, j ust do Wnstream
o f an o utlet o f th e c yc lo ne sep arato r. Prio r to ? ring up th e
h eating c h amb er eac h day, o r af ter any inv o luntary sh utdo Wn,
th e p urge gate Wo uld b e o p ened to essentially c lo se o r th ro ttle
do Wn th e o utlet f ro m th e p ro c ess stream and to admit amb ient
air into th e duc t leading to th e c o f f ee b ean ro asting c h amb er.
Th us, b y means o f th e c irc ulating f an do Wnstream o f th e
ro asting c h amb er, amb ient air Was draWn into and th ro ugh th e
entire system to p urge p o tentially c o mb ustib le ( exp lo siv e)
gases o r p artic ulates th at may h av e ac c umulated, deliv ering
th e air and p artic ulates into th e c yc lo ne sep arato r and th e
h eating c h amb er. Th ese materials Wo uld b e b lo Wn o ut
th ro ugh th e inc ineratio n tub e v ia th e exh aust stac k at its up p er
end, and th e system Wo uld b e p urged and ready to b e ? red.
Alth o ugh th e p atented c o f f ee b ean ro asting system Was
mo stly smo keless, at th e end o f th e ro ast th ere Was smo ke in
th e ro aster and th e b eans c o o ling in amb ient air made mo re
smo ke. Th e smo ke in th e ro aster p rimarily rec irc ulated With
th e p ro c ess stream, and th e v o lume o f smo ke leav ing th e
system th ro ugh th e inc ineratio n tub e o f th e c yc lo ne Wo uld b e
c leaned b y inc ineratio n. Th e b eans in th e c o o ling tray Wo uld
c o ntinue to generate smo ke until f alling b elo W a c ertain tem
20
25
30
35
4 0
4 5
50
55
60
65
2
p erature, and th is typ ic ally h ap p ened ab o ut f o rty- ? v e sec o nds
af ter th e b eans Were dump ed into th e c o o ler at th e end o f a
ro ast. Oth er c o f f ee ro asters h av e used a similar arrangement
f o r c o o ling th e b eans af ter th e ro ast, in a c o o ling tray o utside
th e ro aster.
SUMMARY OF THE I N VEN TI ON
By th e imp ro v ement o f th e c urrent inv entio n, th e smo ke
generated b y c o o ling b eans is no lo nger allo Wed to enter th e
amb ient air, b ut instead is inc inerated in th e inc ineratio n tub e.
I n essenc e, th e inv entio n c o mb ines th e b ean c o o ling step With
an air p urge. At th e end o f th e ro ast, rath er th an dump ing th e
ro asted c o f f ee b eans into th e external c o o ler righ t aWay, th e
neW p ro c ess leav es th e c o f f ee b eans remaining in th e ro aster
to undergo a p erio d o f c o o ling. Wh en th e ro ast is c o mp leted
th e p urge gate is o p ened, sub stantially b lo c king o f f th e p ro
c ess stream ? o W o ut o f th e c yc lo ne, and th e b urner is turned
up to a h igh er v alue. Th is c reates c o nsiderab ly h igh er h eat in
th e inc ineratio n tub e; th is h eat is no t rec irc ulated b ac k to th e
c o f f ee ro asting c h amb er b ec ause th e p urge gate is o p ened,
b lo c king rec irc ulatio n. Fresh air is v ented in th ro ugh th e
p urge gate o p ening and c o o ls th e b eans do Wn signi? c antly,
direc tly in th e ro asting c h amb er, Wh ile at th e same time ? ush
ing o ut th e system f ro m to p to b o tto m and c ausing th e air and
all smo ke and p artic ulate material to exit v ia th e inc ineratio n
tub e. With th e inc ineratio n tub e already h o t f ro m th e ro asting
p ro c ess, and With th e c o ntrib utio n o f additio nal h eat f ro m th e
h igh er- ? ring b urner, th e system ac h iev es v irtually c o mp lete
inc ineratio n o f th e smo ke f ro m th e b eans Wh ile th e b eans
remain in th e ro asting c h amb er and are b eing c o o led. Finally,
Wh en th e b eans are dro p p ed into th e c o o ler th ere is almo st no
smo ke generated, b ec ause muc h o f th e c o o ling h as already
taken p lac e in th e ro aster. Th e time req uired f o r air c o o ling o f
th e b eans in th e ro aster is adj ustab le, b ut c an b e o n th e o rder
o f ab o ut ten sec o nds to o ne minute.
I t is th us amo ng th e o b j ec ts o f th e inv entio n to ac h iev e
v irtually smo keless o p eratio n o f a c o f f ee b ean ro aster o p er
ating o n a c yc lo ne stream p rinc ip le as in US. Pat. N o . 5, 94 4 ,
512, b y simultaneo usly p urging th e ro asting c h amb er o f
smo ke and p erf o rming p reliminary c o o ling o f th e b eans With
amb ient air direc tly in th e ro aster, and inc inerating th e smo ke
f ro m th e b eans and th e ro asting c h amb ers. Th ese and o th er
o b j ec ts, adv antages and f eatures o f th e inv entio n Will b e
ap p arent f ro m th e f o llo Wing desc rip tio n o f a p ref erred
emb o diment, c o nsidered alo ng With th e ac c o mp anying draW
1ngs.
DESCRI PTI ON OF THE DRAWI N G S
FI G . 1 is a p ersp ec tiv e v ieW sh o Wing a c o f f ee b ean ro asting
mac h ine o f th e inv entio n.
FI G . 2 is a side v ieW o f th e c o f f ee b ean ro aster, indic ating
a p ro c ess stream ? o W p ath .
FI G . 3 is a sc h ematic elev atio n v ieW, p artly in p ersp ec tiv e
and p artially in b lo c k diagram f o rm, sh o Wing p ro c ess stream
? o W th ro ugh th e c o f f ee b ean ro aster.
FI G . 3A is a sc h ematic p lan v ieW indic ating a f eature o f th e
inv entio n.
FI G . 4 is a v ieW similar to FI G . 3, b ut sh o Wing th e c o f f ee
b ean ro aster system in a dif f erent mo de.
FI G . 5 is a p ersp ec tiv e v ieW sh o Wing a p urge gate and
ac tuato r inc luded in th e system o f th e inv entio n.
FI G . 6 is a Ho w c h art indic ating th e p ro c ess o f th e inv en
tio n.
US 8, 679, 561 B2
3
DESCRI PTI ON OF PREFERRED
EMBODI MEN TS
FI G . 1 sh o ws a c o f f ee b ean ro aster 10 ac c o rding to th e
inv entio n, generally as desc rib ed in Us. Pat. N o . 5, 94 4 , 512.
Th e o p eratio n o f th e mac h ine, f o r a generic ally desc rib ed
h eating ap p lic atio n, is desc rib ed in th e p atent and th at
desc rip tio n is inc o rp o rated h erein b y ref erenc e.
Th e mac h ine 10 h as a c o f f ee b ean h o p p er 12, a b ean ro ast
ing c h amb er 14 , a c irc ulating f an o r b lo Wer 16 deliv ering a
p ro c ess stream o f gases f ro m th e ro asting c h amb er to a
c yc lo ne sep arato r 18, o nly an up p er p o rtio n o f Wh ic h is seen
in FI G . 1, an inc ineratio n tub e and c h amb er 20 f o r exh aust
f ro m th e c yc lo ne sep arato r, a duc t 22 leading f ro m th e exit o f
th e c yc lo ne sep arato r 18 b ac k to th e ro asting c h amb er 14 ,
c o ntro ls 24 and a b ean c o o ling tray 26 f o r rec eiv ing ro asted
c o f f ee b eans f ro m th e ro asting c h amb er 14 . Th e c o ntro ls 24
inc lude a c o mp uter p ref erab ly With a to uc h sc reen mo nito r f o r
user inp ut and system mo nito ring, th e p ro gramming in th e
c o mp uter o p erating th e system in ac c o rdanc e With inp uts
selec ted b y an o p erato r.
FI G . 2 sh o Ws th e mac h ine 10 in side v ieW and indic ates a
p ro c ess stream ? o W p ath th ro ugh th e ro asting c h amb er 14
( th e inside o f Wh ic h is exp o sed in FI G . 2, rev ealing b ean
sif ting b lades 28) , and th ro ugh a duc t 30, th ro ugh th e c irc u
lating f an 16 and into th e c yc lo ne sep arato r 18. Exiting th e
c yc lo ne sep arato r, th e p ro c ess stream, as no ted ab o v e, ? o Ws
th ro ugh th e duc t 22 and b ac k into th e b ean ro asting c h amb er
14 .
FI G . 3 sh o Ws th e ? o W o f th e p ro c ess stream during no rmal
o p eratio n, i. e. c o f f ee b ean ro asting. Th is o p eratio n is f ully
exp lained in U. S. Pat. N o . 5, 94 4 , 512 ( alth o ugh no t sp ec i?
c ally f o r c o f f ee b eans) and Will b e b rie? y exp lained h ere. Th e
c o f f ee b eans in th e ro asting c h amb er 14 are ro asted b y th e
h eated p ro c ess stream ? o Wing th ro ugh th e c h amb er. Th e c ir
c ulating f an 16 draWs th e p ro c ess stream th ro ugh and o ut o f
th e ro asting c h amb er and deliv ers th e stream tangentially into
a p ro c ess stream inlet 32 o f th e c yc lo ne sep arato r 18. Th is
regio n o f th e c yc lo ne sep arato r h as a sealing 34 , and a c ylin
dric al b af ? e 36 de? nes an inner b o undary, so th at th e p ro c ess
stream sWirls aro und in th e manner sh o Wn b y arro Ws 38 in th e
draWing, desc ending do Wn into th e c o nic ally- sh ap ed lo Wer
p o rtio n 4 0 o f th e sep arato r and ? o Wing aro und a h eat so urc e
4 2, p ref erab ly a gas ? ame as sh o Wn. Th e p ro c ess stream is
h eav ier th an th e h o t gases rising With th e ? ame, Wh ic h enter
th e lo Wer end 4 4 o f th e inc ineratio n tub e 20, and th us th e
p ro c ess stream mingles v ery little With th e c o mb ustio n gases
o f th e ? ame 4 2.
Th e c yc lo ne sep arato r de? nes a h eating c h amb er aro und
th e h eat so urc e 4 2, muc h o f th is h eating c h amb er b eing
de? ned in th e c o nic al sec tio n 4 0.
Th e p ro c ess stream is h eated b y p ro ximity to and p artial
c o ntac t With th e h eat so urc e 4 2 and b y c o ntac t With th e Wall o f
th e c o nic al sec tio n 4 0, as Well as With th e exterio r o f th e
inc ineratio n tub e 20. Af ter th e stream h as sWirled do Wn into
th e h eating c h amb er, Wh ic h o c c urs b y inertia o f do WnWard
mo v ement, it rises, in th e same sWirling p attern, sWirling
aro und th e inc ineratio n tub e 20 and With in th e b af ? e 36 up to
an up p er c h amb er 4 6 and o ut o f th e c yc lo ne sep arato r th ro ugh
a p ro c ess stream o utlet at 4 8. Wh ile in th e c yc lo ne sep arato r,
th e p ro c ess stream sWirls at a c o nsiderab le rate o f sp eed,
sep arating p artic les o ut f ro m th e stream b y c entrif ugal f o rc e,
th o se p artic les th en dro p p ing do Wn alo ng th e Walls o f th e
c o nic al sec tio n 4 0 and o ut o f th e h eating c h amb er, do Wn into
a c h af f b in o r h o p p er 50.
Do Wnstream o f th e p ro c ess stream o utlet 4 8 o f th e c yc lo ne
sep arato r, th e p ro c ess stream enters th e duc t 22, p assing b y a
20
25
30
35
4 0
4 5
50
55
60
65
4
p urge gate 52 Wh ic h is in its no rmal p o sitio n aligned With an
o uter Wall o f th e duc t 22, th us simp ly de? ning a p o rtio n o f th e
duc t Wall. Th is is its p o sitio n during ro asting o f c o f f ee b eans,
and is indic ated sc h ematic ally in FI G . 3A.
As indic ated b y th e arro W 56 in FI G . 3, th e p ro c ess stream
rec irc ulates b ac k to th e ro asting c h amb er, and th is c o ntinues
under th e mo v ing f o rc e o f th e c irc ulating f an o r b lo Wer 16
during th e ro ast. During th is time, so me o f th e smo ke gener
ated b y th e ro asting b eans is inc inerated in th e inc ineratio n
tub e 20, b y rep eated p asses th ro ugh th e c yc lo ne sep arato r.
Ho Wev er, b ec ause o f limited mingling With th e c o mb ustio n
gases f ro m th e ? ame 4 2, muc h o f th e smo ke remains in th e
p ro c ess stream and in th e ro asting c h amb er.
At th e c o mp letio n o f a ro ast, in th e o p eratio n o f th e
mac h ine as desc rib ed in th e p atent, th e ro asted, h o t b eans
Were released into th e c o o ling tray 26 ( FI G . 1) , Wh ere th ey
Were c o o led, With smo ke released to amb ient air.
As exp lained in th e p atent, c o ntro llers are inc luded in th e
system at 58 and 60, f o r c o ntro lling th e h eigh t o f th e ? ame 4 2
b ased o n exh aust gas temp erature at th e exh aust stac k 62 o f
th e inc ineratio n tub e, and f o r c o ntro lling th e c o mb ustib le
mixture f o r th e h eat so urc e v ia a v alv e 64 c o ntro lled in ac c o r
danc e With th e temp erature in th e ro asting c h amb er.
Alth o ugh no t exp lained in th e p atent, th e p urge gate 52 Was
inc luded in th e c o f f ee ro asting ap p aratus 10. I ts p urp o se Was
to c lear th e system o f p o tentially exp lo siv e gases and p artic u
late materials b ef o re ignitio n o f th e h eat so urc e 4 2. Th is must
b e do ne b ef o re ? ring up th e ro aster in th e mo rning, o r at any
o th er time Wh en th e h eating h as b een sh ut do Wn f o r any
reaso n. Fo r th is p urp o se th e p urge gate Was sWung o p en, as
sh o Wn in FI G . 5, and at th is inwardly- swung p o sitio n th e gate
52 Wo uld p ro v ide a large v ent o p ening into th e duc t 22. At th e
same time th e inWardly sWung gate 52 Wo uld sub stantially
b lo c k th e ? o W o ut o f th e c yc lo ne sep arato r v ia th e p ro c ess
stream o utlet 4 8. Th us, With th e h eat so urc e 4 2 sh ut do Wn, th e
p urge gate 52 Wo uld b e sWung inWard to th e p urge p o sitio n
and th e c irc ulating f an 16 ac tiv ated, th us c leaning o ut any
p o tentially exp lo siv e gases o r airb o rne p artic ulates, b y draW
ing amb ient air th ro ugh th e ro asting c h amb er and into th e
c yc lo ne sep arato r, b ut With th at stream exiting up th ro ugh th e
inc ineratio n tub e 20 and o ut th e stac k 62, sinc e th is is th e o nly
exit av ailab le f o r th e mo v ing air in th is mo de o f o p eratio n. I n
FI G . 3A th e p urge gate 52 f o r th is mo de Wo uld b e in th e
p o sitio n sh o Wn in dash ed lines.
As exp lained ab o v e, th e inv entio n utiliZes th e p urge gate
and th e p urge f unc tio n in a dif f erent Way. FI G . 4 illustrates
o p eratio n in th e mo de o f th e inv entio n.
I n FI G . 4 a ro ast h as j ust b een c o mp leted, and th e h eat
so urc e 4 2 remains ac tiv ated. Th e p urge gate 52 is sWung
inWardly, essentially b lo c king ? o W o ut o f th e c yc lo ne sep a
rato r and o p ening an air v ent into th e duc t 22. As in a p re
? ring p urge o f p artic ulates as disc ussed ab o v e, th is c auses
? o W th ro ugh th e ro asting c h amb er and into th e c yc lo ne sep a
rato r, b ut th en up th ro ugh th e inc ineratio n tub e 20 and o ut th e
stac k 62. I n th is c ase, h o Wev er, th e h eating ? ame 4 2 is ac tiv e
and p ref erab ly is turned h igh er. Th e amb ient air entering b y
th e p urge gate and indic ated b y arro Ws 70 in FI G . 4 c o o ls th e
c o f f ee b eans Wh ile th ey remain in th e ro asting c h amb er 14 .
Th e ro asted b eans are p rec o o led in ap p ro ximately ten to sixty
sec o nds b y th is amb ient air. Th ey are c o o led b elo W a tem
p erature at Wh ic h th ey generate smo ke. I mp o rtantly, smo ke is
sub stantially remo v ed f ro m th e b eans and f ro m th e ro asting
c h amb er, and any smo ke Wh ic h h as remained in th e p ro c ess
stream is also remo v ed. Th is ? o W o f smo ke, gases and air is
f o rc ed up th ro ugh th e inc ineratio n tub e 20, Wh ic h is p ref er
ab ly at h igh er temp erature no W to h andle th e rap idly mo v ing
US 8, 679, 561 B2
5
? o W o f p o llutants, and th o se p o llutants are inc inerated b ef o re
b eing disc h arged o ut th e stac k 62.
I n th is mo de o f o p eratio n o f th e b ean ro asting ap p aratus,
th ree th ings are ac c o mp lish ed to a v arying degree b ased o n
th e time duratio n c h o sen b y th e o p erato r: th e c o f f ee b eans are
q uic kly c o o led b y th e ? o W o f amb ient air th ro ugh th e b ean
ro asting c h amb er, to p o tentially b elo W smo king temp erature;
th e b ean ro asting c h amb er is p urged o f smo ke and p artic ulate
material; and th e smo ke and p artic les are mo v ed b y th e c ir
c ulating b lo Wer th ro ugh th e c yc lo ne sep arato r and up th ro ugh
th e inc ineratio n tub e, and inc inerated. Th e mac h ine 10 th ere
f o re c an b e o p erated to b e v irtually c o mp letely smo keless.
Th e degree o f c o o ling With in th e c h amb er is under th e c o ntro l
o f th e o p erato r. Th e lo nger th e mac h ine runs in air c o o l mo de,
th e mo re smo ke is reduc ed, b ut th e b eans are no t c o o ling as
f ast as Wh en th ey are in th e external c o o ler, so th e o p erato r
( ro astmaster) may Want to mo v e th e b eans o ut o f th e c h amb er
as so o n as p rac tic ab le so as no t to af f ec t th e ? av o r o f th e
c o f f ee. So me small amo unt o f smo ke may still b e p ro duc ed
dep ending o n h o W lo ng internal air c o o l c yc le is allo Wed to
run and h o W dark th e p artic ular ro ast is. Th is is at th e ro ast
masters disc retio n.
FI G . 5 sh o Ws main p arts o f a mec h anism f o r o p ening and
c lo sing th e p urge gate 52. Th e p urge gate is attac h ed to a
v ertic ally o riented sp indle 72 adj ac ent to th e air o p ening. A
c rank arm 74 ( seen o nly in edge v ieW) is sec ured to th e sp indle
72, so as to ro tate th e sp indle and o p en o r c lo se th e gate 52 v ia
a p neumatic c ylinder 76 With a linkage 78 to th e c rank arm.
Th e ac tuating c ylinder 76 is c o ntro lled elec tro nic ally and b y
so f tWare inc luded With th e ro asting mac h ine. Th e so f tWare
inc ludes p ro gramming f o r o p erating th e p urge gate 52 as
desc rib ed ab o v e, so th at th e gate is o p ened f o r a p resc rib ed
and/ o r o p erato r- selec ted p erio d o f time, Wh ile th e c irc ulating
f an c o ntinues to o p erate, immediately af ter a ro ast is c o m
p leted. Th e c irc ulating f an sp eed may b e auto matic ally
inc reased as th e c irc ulating f an setting is inc reased. As
exp lained ab o v e, th e so f tWare o r lo gic o f th e system also
p urges air th ro ugh th e system j ust p rio r to eac h time th e h eat
so urc e is ? red up .
I f needed, th e inc ineratio n tub e 20 and inc ineratio n c h am
b er/ stac k c an b e made lo nger, o r o f larger diameter, to p ro v ide
suf ? c ient dWell time f o r f ull inc ineratio n o f smo ke and p o l
lutants. Th is is no t nec essary if th e ? ame 4 2 is turned h igh
eno ugh f o r th e sh o rt p erio d o f time during Wh ic h th e air
c o o ling/ smo ke inc inerating c yc le is o p erated, Wh ic h c an b e a
matter o f sec o nds, less th an o ne minute. N o te also , th e c irc u
lating f an 16 is sh o Wn in a p ref erred p o sitio n j ust up stream o f
th e inlet to th e c yc lo ne sep arato r, b ut it c o uld b e p o sitio ned
j ust up stream o f th e ro asting c h amb er if desired, and similar
results Wo uld b e ac h iev ed. Also , th e p urge gate 52, alth o ugh
c o nv eniently o p erated in th e f o rm sh o Wn, c o uld b e c o n? gured
dif f erently. I t c o uld b e lo c ated f arth er do Wnstream in th e duc t
( alth o ugh th is Wo uld p rev ent p urging o f th e duc t 22 in a
p re- ? ring p urge o f p artic ulates, and th us migh t b e o b j ec tio n
ab le) , o r a gate c o uld b e p ro v ided to c lo se o f f th e p ro c ess
stream o utlet 4 8 o f th e c yc lo ne sep arato r, and a dif f erent gate
o r do o r c o uld b e o p ened to v ent amb ient air into th e duc t 22 o r
into th e ro asting c h amb er 14 .
N o te also , th e mac h ine and p ro c ess desc rib ed h erein are
no t limited to c o f f ee b eans, b ut c an b e used With c o c o a b eans
o r o th er b eans o r grains to b e ro asted, p artic ularly th o se th at
generate smo ke in ro asting.
Th e ? o W c h art o f FI G . 6 indic ates th e p ro c ess o f a c o f f ee
ro asting c yc le ac c o rding to th e inv entio n, in th is examp le
illustrating th e p ro c ess f ro m startup , Wh en th e mac h ine h as
b een c o mp letely o f f .
20
25
30
35
4 0
4 5
50
55
60
65
6
Th e o p erato r turns o n th e p o Wer as indic ated in th e b lo c k
80. Th e c o f f ee b eans are p lac ed in th e h o p p er, o r h av e already
b een p lac ed, as at 82. Th e o p erato r p resses a b urner start
b utto n and th e system enters an idle mo de ( b lo c k 84 ) . Th e
b urner is no t immediately ignited. Th e b urner is no t immedi
ately ignited. Th e p urge gate is o p ened ( o r may already b e
o p en) and th e c irc ulatio n f an o r c irc ulating f an o r b lo Wer is
turned o n, as no ted in th e b lo c k 86. Th e c irc ulatio n f an needs
a p erio d o f time to ramp up to sp eed. Dep ending o n th e siZe o f
th e system, th e system p urge c o ntinues f o r ab o ut tWenty
sec o nds to sixty sec o nds, remo v ing any smo ke o r airb o rne
p artic ulates th at may b e in th e system p rio r to igniting th e
b urner. Wh en th e p urge is c o mp leted, th e c irc ulatio n f an
sp eed is auto matic ally lo Wered ( b lo c k 88) , and th e p urge gate
is c lo sed, indic ated at 90.
Af ter c o mp letio n o f th e p urge and c lo sing o f th e p urge gate,
th e b urner ligh ts, and th e ro aster is allo Wed to Warm up f o r an
ap p ro p riate p erio d o f time, as at th e b lo c k 92. Wh en th e
ro aster c h amb er is su? ic iently Warm, th e b eans are dro p p ed
into th e ro ast c h amb er f ro m th e h o p p er, b lo c k 94 . Th e system
no W enters th e ro ast mo de ( b lo c k 96) , in Wh ic h th e b urner is
h eating rec irc ulating air and gases Wh ic h c irc ulate th ro ugh
th e ro asting c h amb er to ro ast th e b eans. A drum in th e ro ast
ing c h amb er is ro tating during th e ro ast, o r mo re p ref erab ly,
ro tating p addles in a statio nary drum agitate th e b eams and
assure ev en ro asting. Air agitatio n c an b e used, rath er th an
mec h anic al agitatio n. Th e c irc ulatio n f an setting c an b e c o n
tro lled b y th e o p erato r o r b y a selec ted auto matic mo de. Th e
b urner setting c an also b e selec ted, manually o r auto mati
c ally.
At th e end o f th e ro ast, Wh ic h is indic ated in th e b lo c k 98,
a dec isio n is made b y th e o p erato r o r v ia an auto matic mo de
( b lo c k 100) as to Wh eth er th e air c o o l c yc le Will b e used. I f
so , th e air c o o l c yc le b egins, b lo c k 102. I f no t, th e system go es
into p o st ro ast mo de as indic ated in th e b lo c k 104 . Wh eth er
th e system enters th e air c o o l c yc le c an b e p reset p rio r to
o p eratio n o f th e ro ast c yc le.
Fo r th e air c o o l c yc le, th e b urner setting is inc reased as
no ted at 106, and th e c irc ulatio n f an setting is also inc reased,
as at 108. Th ere may b e a sh o rt delay b ef o re th e c irc ulatio n
f an inc rease, to giv e th e b urner ? ame time to inc rease. Af ter
th e c irc ulatio n f an ? ash b lo Wer sp eed is inc reased, th ere p ref
erab ly is imp o sed a sh o rt delay, e. g. th ree sec o nds, b ef o re th e
p urge gate is o p ened, as no ted in th e b lo c k 110.
Th e b lo c k 112 indic ates th at th e air c o o l c yc le, c o o ling th e
b eans in th e ro aster, p ro c eeds f o r ab o ut ten sec o nds to sixty
sec o nds. Fresh air is draWn in th ro ugh th e o p en p urge gate and
c o urses th ro ugh th e ro aster, c o o ling th e c o f f ee b eans and
mo v ing th e residual smo ke o ut th ro ugh th e inc ineratio n tub e
and stac k. Th e drum ( o r p addles) in th e ro aster c o ntinues to
ro tate, turning o v er th e b eams. Th e drum in th e ro aster c o n
tinues to ro tate, turning o v er th e b eans. As th e b eans are
c o o ling in th e ro asting c h amb er, th e h o t air h eated b y th e
b urner at th is h igh setting do es no t rec irc ulate b ac k to th e
ro aster b ec ause th e p urge gate is o p en, b lo c king th e rec irc u
latio n p ath . All gases and airb o rne p artic ulates exit th ro ugh
th e inc ineratio n tub e and stac k. Af ter th e time p reset f o r air
c o o l, o r as c o ntro lled b y th e o p erato r manually, th e air c o o l
c yc le ends, as no ted in th e b lo c k 114 . Th is is signaled b y th e
to uc h sc reen mo nito r unit 24 , seen in FI G . 1. Th e drum o r
p addles c ease to ro tate.
At th e end o f th e air c o o l c yc le, th e ro asted and p artially
c o o led b eans are released to th e exterio r c o o ling tray as no ted
at 116. Th is c an h ap p en auto matic ally, as p reset, o r th e o p era
to r c an initiate th is manually. Th e p o st ro ast b egins, as no ted
at 118. Th e c irc ulatio n f an is reduc ed to a lo Wer setting ( b lo c k
120) , and af ter a delay, e. g. tWenty sec o nds as indic ated, th e
US 8, 679, 561 B2
7
p urge gate is c lo sed as no ted at 122 and th e b urner ? ame is
reduc ed to a lo W ? re, as no ted at 124 .
At th is p o int, p o st ro ast mo de c o ntinues. Th is mo de c o n
tinues f o r a p reset time, eg ab o ut th ree minutes. I f a neW
b atc h o f b eans is no t mo v ed into th e ro asting c h amb er b ef o re
th e p o st ro ast p erio d ends, as no ted in th e dec isio n b lo c k 128,
th e system Will transitio n into idle mo de 130. I n th is mo de th e
b urner, Wh ic h is at lo W ? re, c an b e p reset to c yc le b etWeen tWo
set temp eratures to keep th e system f ro m h eating up mo re
th an desired. Alternativ ely, th e b urner c an b e sh ut o f f .
I f a neW b atc h o f b eans is dro p p ed into th e c h amb er ( dec i
sio n b lo c k 128) , a neW ro ast c yc le Will b egin, as at th e b lo c k
94 . N o te th at th e green c o f f ee b eans sh o uld no t b e dro p p ed
into th e c h amb er if th e b urner is o f f , and th e sc reen Will th us
instruc t th e o p erato r.
Th e so f tware- c o ntro lled mac h ine and p ro c ess h av e mul
tip le f unc tio nalities. With th e p ro grammed c o mp uter and
o p erato r inp uts f o r selec ted settings, th e mac h ine c an v ary th e
c irc ulating f an sp eed as needed o r desired; th e b urner setting
c an b e inc reased o r dec reased as needed; th e p urge gate is
o p ened and c lo sed f o r dif f erent p urp o ses as set f o rth ab o v e;
and th e o p ening o f th e b eam disc h arge do o r to th e c o o ler c an
b e delayed o r mo di? ed as desired, dep ending o n internal air
c o o ling time selec ted. Th e c o mp uter eq uip ment p ref erab ly
inc ludes a to uc h sc reen mo nito r f o r o p erato r inp ut as Well as
disp lay. Th e c o mp uter and inp ut sc reen are sh o Wn in FI G . 1.
Alth o ugh th e mac h ine and p ro c ess o f th e inv entio n are
desc rib ed p rimarily f o r c o f f ee b ean ro asting, o th er ro astab le
b eans and grains, p artic ularly th o se th at giv e o f f smo ke, c an
b e ro asted. Th e c laims are to b e interp reted as ap p lying to
suc h o th er b eans and grains.
Th e ab o v e desc rib ed p ref erred emb o diments are intended
to illustrate th e p rinc ip les o f th e inv entio n, b ut no t to limit its
sc o p e. Oth er emb o diments and v ariatio ns to th ese p ref erred
emb o diments Will b e ap p arent to th o se skilled in th e art and
may b e made With o ut dep arting f ro m th e sp irit and sc o p e o f
th e inv entio n as de? ned in th e f o llo Wing c laims.
I c laim:
1. A meth o d f o r o p erating a ro aster f o r c o f f ee b eans o r o th er
b eans o r grains, o f th e typ e h av ing a c yc lo ne sep arato r h eating
c h amb er and a c o f f ee b ean ro asting c h amb er, With th e o utlet
o f th e c yc lo ne sep arato r b eing c o nnec ted b y duc ting to th e
c o f f ee b ean ro asting c h amb er f o r h eating c o f f ee b eans th erein
and th e ro asting c h amb er h av ing an o utlet c o nnec ted to an
inlet o f th e c yc lo ne sep arato r, th e c yc lo ne sep arato r h eating
tub e h av ing an inc ineratio n tub e p o sitio ned ab o v e a h eat
so urc e so th at th e p ro c ess stream sWirls aro und th e o utside o f
th e inc ineratio n tub e, and With a c irc ulatio n f an o r b lo Wer
p o sitio ned in th e p ro c ess stream to mo v e th e p ro c ess stream in
a rec irc ulating lo o p th ro ugh th e c yc lo ne sep arato r h eating
c h amb er and th ro ugh th e ro asting c h amb er, c o mp rising th e
step s o f :
20
25
30
35
4 0
4 5
50
8
rec irc ulating th e p ro c ess stream With th e h eat so urc e ac ti
v ated, f o r a su? ic ient time and at a su? ic ient temp erature
o f th e p ro c ess stream to ro ast c o f f ee b eans in th e ro asting
c h amb er,
Wh en th e c o f f ee b eans h av e b een ro asted, leav ing th e c o f f ee
b eans remaining in th e ro asting c h amb er f o r a time to
allo W c o o ling,
o p ening an amb ient air v ent b etWeen th e c yc lo ne sep arato r
and th e ro asting c h amb er Wh ile at th e same time sub
stantially b lo c king ? o W o ut o f th e c yc lo ne sep arato r,
th us c ausing amb ient air to Ho w into and th ro ugh th e
ro asting c h amb er c o o ling th e c o f f ee b eans and into th e
c yc lo ne sep arato r, th en into th e inc ineratio n tub e, Wh ere
th e air c arrying smo ke f ro m th e ro asting c h amb er and
airb o rne p artic ulate material is inc inerated b ef o re b eing
exh austed,
Wh ereb y, f o llo Wing a ro asting o f c o f f ee b eans, th e ro asting
c h amb er is p urged o f smo ke and airb o rne p artic ulate
matter, th e c o f f ee b eans are c o o led b elo W a temp erature
at Wh ic h th ey giv e o f f smo ke, and all smo ke, p o llutants
and airb o rne p artic ulate matter are inc inerated, suc h th at
th e ro asting p ro c ess p ro duc es almo st no smo ke o utside
th e mac h ine.
2. Th e meth o d o f c laim 1, Wh erein, Wh ile th e amb ient air
v ent is o p en and Ho w is sub stantially b lo c ked o ut o f th e
c yc lo ne sep arato r, th e h eat so urc e is at a h igh setting and th e
c irc ulating f an o r b lo Wer is at a h igh er sp eed th an during
c o f f ee b ean ro asting, so th at th e p urged smo ke and airb o rne
p artic ulate material is f ully inc inerated in th e inc ineratio n
tub e.
3. Th e meth o d o f c laim 1, Wh erein th e step s o f o p ening an
amb ient air v ent and sub stantially b lo c king ? o W o ut o f th e
c yc lo ne sep arato r, c o mp rise auto matic ally c h anging th e p o si
tio n o f a p urge gate in said duc ting, f ro m a c lo sed p o sitio n
sealing against amb ient air and allo Wing p ro c ess stream Ho w
to th e b ean ro asting c h amb er, to an o p en p o sitio n sub stan
tially b lo c king ? o W o ut o f th e c yc lo ne sep arato r and o p ening
th e duc ting do Wnstream o f th e p urge gate to Ho w o f amb ient
air to th e b ean ro asting c h amb er.
4 . Th e p ro c ess o f c laim 1, Wh erein th e time and temp era
ture o f ro asting th e c o f f ee b eans, th e o p ening o f th e amb ient
air v ent and sub stantially b lo c king ? o W o ut o f th e c yc lo ne
sep arato r, are c o ntro lled auto matic ally b y a c o mp uter and
p ro gramming.
5. Th e meth o d o f c laim 1, f urth er inc luding, af ter a p erio d
o f time in Wh ic h th e c o f f ee b eans in th e ro asting c h amb er are
c o o led, auto matic ally releasing th e c o f f ee b eans f ro m th e
c h amb er into an exterio r c o o ling tray, lo Wering th e sp eed o f
th e c irc ulatio n f an o r b lo Wer, c lo sing th e amb ient air v ent and
allo Wing ? o W o ut o f th e c yc lo ne sep arato r, and reduc ing th e
setting o f th e h eat so urc e.
* * * * *