This application claims priority from U.S. Provisional Application Serial No. 63/230,918 filed August 9, 2021, the entire contents of which is hereby incorporated by reference.

FIELD OF THE INVENTION

[0001] The present invention relates to a countertop appliance for use in dough and bread making. In particular the present invention relates to an appliance for preparing and maintaining a sourdough starter by automating the process.

BACKGROUND OF THE INVENTION

[0002] Sourdough bread making generally involves a long process of fermentation of flour and water by airborne yeasts and lactobacillus organisms that are present in the environment. In a nutshell, sourdough is produced by mixing flour and water and allowing a slow- fermentation process by naturally occurring microorganisms to produce a sourdough starter. Sourdough is unique in that it does not require the addition of commercial yeast in order to rise. Instead, live organisms in the fermented sourdough starter act as a natural leavening agent. Sourdough breads are known for their characteristic tang}' flavor, chewy texture, and crisp crust. The naturally-occurring acetic and lactic acids, and long fermentation times help to break down gluten in the four, making it easier for the body to absorb.

[0003] Many sourdough enthusiasts make their own sourdough breads at home. The process of sourdough bread making requires some effort to produce and actively maintain a starter from which bread can be produced. While numerous recipes exist for making a sourdough starter, generally speaking flour and water are combined to form a mixture that will begin to ferment under the influence of naturally occurring yeasts and bacteria present in the mixture. A small portion of the live culture is used to make bread dough rise. Sourdough starters must be kept alive by regular feedings of flour and water to maintain their strength for maximum rising power. Generally, this involves removing a portion of an existing culture and then “feeding” the remaining portion with flour and water. Then, the mixture is allowed to rest at room temperature or in a warm spot (75° - 80° F is ideal) until it becomes bubbly and active. The starter is ready to use when it doubles in size. This can take anywhere from 2-12 hours or more, depending on the temperature and other conditions associated with the starter.

[0004] There remains a need for a device to automate and simplify the process of starting, maintaining, and feeding a sourdough starter.

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SUBSTITUTE SHEET (RULE 26) [0005] The present invention provides a countertop appliance or device for automating the process of adding flour and water, mixing, and removing excess starter.

SUMMARY OF THE INVENTION

[0006] The present invention relates to a countertop device or appliance that can be used to create, maintain, and feed a sourdough starter by automating the processes of adding flour and water, mixing, and removing excess starter. Flour and water are stored in reservoirs attached to the device. Periodically, portions of flour and water are added to a dual mixing and fermentation chamber containing the starter. In an embodiment, the device can be controlled automatically by a program running on a microcontroller to connect with an app which can be installed on a user’s phone. Alternatively, the device can be controlled manually by a user through an interface on the device. Operation of the device can simplify the process of preparing and using sourdough starters, thereby saving time and money.

[0007] It is an object of the present invention to provide a countertop appliance for starting or maintaining and feeding a sourdough starter by automating the processes of adding flour and water, mixing, and removing excess starter.

[0008] It is another object of the present invention to provide a countertop device for starting or maintaining and feeding a sourdough starter where the device can be controlled manually by a user, or automatically by a program running on a microcontroller with the ability to wirelessly connect to an app which can be installed, for example, on a user’s phone.

[0009] It is another object of the present invention to provide a method for starting and/or maintaining a sourdough starter by use of an appliance of the invention.

[0010] These and other objects and advantages of the present invention will be apparent from the following description, the accompanying drawings, and the appended claims. This Summary is provided merely to introduce certain concepts and not to identify any key or essential features of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The drawings provided herein form a part of the specification and are to be construed in conjunction therewith. Like reference numbers have been employed throughout wherever possible to indicate like or similar parts in the various views and embodiments.

[0012] Fig. 1 A is a block diagram showing components of a housing base of an embodiment of an appliance of the invention. [0013] Fig. IB is a block diagram showing components of a fermentation and mixing chamber of an embodiment of an appliance of the invention.

[0014] Fig. 2 is a block diagram showing input components of an embodiment of a device of the invention.

[0015] Fig. 3 is a block diagram showing output components of an embodiment of a device of the invention.

[0016] Fig. 4 is a block diagram showing functions that may be performed by an embodiment of an appliance of the invention using a software application.

[0017] Fig. 5 is a block diagram showing a sourdough starter feeding schedule data structure.

[0018] Fig. 6 provides a flow chart for preparing a device of the invention for normal operation.

[0019] Fig. 7 provides a flow chart illustrating use of a device of the invention in the preparation of a sourdough starter.

[0020] Fig. 8 provides a flow chart of a method for emptying the waste chamber of a device of the invention.

[0021] Fig. 9 provides a flow chart of a method for modifying a feeding schedule of an embodiment of a device of the invention.

[0022] Fig. 10 provides a flow chart for determining the state of a device of the invention and communicating with the user.

[0023] Fig. 11 provides a flow chart for automatically feeding a sourdough starter according to an embodiment of the invention.

[0024] Fig.12 provides a perspective view of an embodiment of a sourdough starter device of the invention.

[0025] Fig. 13 provides an exploded view of the device shown in Fig. 12.

[0026] Fig. 14 provides a perspective view of a housing base of an embodiment of a device of the invention.

[0027] Fig. 15 provides a front perspective view of an embodiment of a mixing chamber assembly of the invention.

[0028] Fig. 16 shows a top view of the mixing chamber assembly shown in Fig. 15.

[0029] Fig. 17 shows a bottom view of the mixing chamber assembly shown in Fig. 15.

[0030] Fig. 18 shows a side view of the mixing chamber assembly of Fig. 15.

[0031] Fig. 19 shows a side sectional view of the mixing chamber assembly of Fig. 15.

[0032] Fig. 20 shows an enlarged portion (indicated by the dashed circle) of the sectional view in Fig. 19.

[0033] Fig. 21 shows a front view of an embodiment of a device of the invention. [0034] Fig. 22 shows a side sectional view of the device in Fig. 21.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0035] As used herein the terms “starter” or “sourdough starter” refer to a mixture of flour and water that is populated by, or hosts, a variety of naturally-occurring bacteria and yeasts, used to leaven new bread dough.

[0036] As used herein the terms “old starter” or “sourdough discard” or “excess starter” refer to a portion of an active starter that is removed before feeding the remaining starter. An old starter may not be active enough to make bread dough rise though it may be used for other baking applications or for making a new starter.

[0037] As used herein the terms “fermentation and mixing chamber” and “mixing chamber” are used interchangeably to refer to a chamber or vessel that receives flour and water for creating or maintaining a sourdough starter.

[0038] A device of the invention is a countertop appliance which, in some embodiments, can be used to create new sourdough starters, or to maintain and feed existing sourdough starters by automating the processes of adding flour and water, mixing, and removing excess starter according to a feeding schedule. Flour and water are stored in reservoirs on the device, and periodically added to a mixing chamber to feed an already-existing starter, or to produce a new starter. In one embodiment, the device is controlled automatically by a program running on a microcontroller or computing device in the device with the ability to wirelessly connect to an app which can be installed on a user’s phone. Operation of the device can also be controlled manually by a user interacting with an interface on the device.

[0039] In one embodiment, the device includes a physical interface that enables a user to enter operational instructions. For example, an interface may include buttons that can be pressed, or a touch screen that can be activated to specify aspects of the process including, but not limited to, the amount of flour and water to be added to the mixing chamber, as well as the frequency thereof.

[0040] The device stores flour and water in separate reservoirs that periodically need to be refilled by the user. In one embodiment, sensors can be included in the reservoirs to notify the user when additional water and/or flour are needed, for example, by emitting a signal such as a light signal, sound signal, or other electronic signal.

[0041] In a preferred embodiment, a control system located in the appliance allows a user to automate and customize the process of adding flour and water to the mixing chamber for feeding an existing starter, or for creating a new starter. For this purpose, the device may include a microcontroller or computing device with programmable timers and I/O for reading sensors and controlling the mixer and water pump of the device. An app can provide notifications to a user advising of the status of ongoing processes, amounts of flour and water present in the reservoirs, as well as providing recipes and access to a storefront offering supplies, replacement parts, and other related items.

[0042] With reference now to the Figures, certain preferred embodiments of the invention will now be described in greater detail. Some features illustrated in the Figures are not drawn to scale. It should be understood that the invention is not limited to the precise forms or sizes of the preferred embodiment s), apparatus, device, method, or material, as disclosed hereinbelow, and that changes thereto may be made without departing from the scope thereof.

[0043] Fig. 1 A is a block diagram showing certain physical components of a housing unit or base that may be included in an embodiment of a device of the invention. A housing base includes a mixer motor 52, network interface 500, waste chamber 14, flour reservoir 1, power supply 520, input component 540, flour auger 9, computing device 560, output component 580, flour augur motor 54, display 6, water reservoir 2, mixer interlock component 700, one or more environmental sensors 205, water pump 8, memory 710, mixing chamber valve actuator 720, and UI buttons and indicator lights 350.

[0044] Mixer motor 52 drives the shaft of the mixer which mixes flour and water inside the mixing chamber.

[0045] Network Interface 500 provides an interface for connecting to and communicating with other devices such as a home wireless network, or an application running on a smartphone.

[0046] Waste Chamber 14 provides a receptacle for holding old starter. When the mixing chamber’s valve is opened, starter exits from the bottom of the mixing chamber through a hole in the housing base into the waste chamber. Waste chamber 14 can be removed from the housing base for disposal of old starter or for cleaning.

[0047] Flour reservoir 1 provides a receptacle for storing flour.

[0048] Power Supply 520 accepts power from a regular home outlet and provides power to the electronic components of the device.

[0049] Input Component 540 provides inputs from environmental sensors to the computing device.

[0050] Flour auger 9 moves flour from the flour reservoir to the mixing chamber.

[0051] Computing Device 560 processes sensor and user inputs to determine outputs to control the device’s operation and stores operational settings. [0052] Output Component 580 takes outputs from the computing device to control physical components of the device such as motors.

[0053] Flour auger motor 54 activates the flour auger 9 to move flour from the flour reservoir to the mixing chamber.

[0054] Display 6 provides a visual display, such as an LCD display, on the exterior of the device to display information to a user. Information shown to a user may include warnings, faults, timers, schedules of operation, recipes, or device settings, or any combination thereof.

[0055] Water Reservoir 2 is a vessel for holding water. Water is transported from the vessel by a water pump to the mixing chamber during operation.

[0056] Mixer interlock component 700 enables reversible coupling of the mixer motor to the mixer. Mixer interlock component 700 lifts a socket which reversibly attaches the mixer motor shaft to the shaft of the mixer, thereby decoupling the mixer motor from the mixer shaft and permitting the mixing chamber to be removed from the housing base.

[0057] Environmental Sensors 205 can be incorporated with a device of the invention to detect levels of flour and water in the respective reservoirs, prevent mixing chamber overflow, and detect the proper function of the device.

[0058] Water Pump 8 moves water from the water reservoir into the mixing chamber.

[0059] Memory 710 stores persistent and operational memory used by the computing device, and may contain recipes consisting of quantities of flour and water, and schedules of mixing and removing excess starter. Memory may also contain logs of device operation and networking information.

[0060] Chamber valve actuator assembly 720 is operable to press valve actuator button on the mixing chamber, thereby compressing a spring and opening the valve on the bottom of the mixing chamber.

[0061] UI Buttons and Indicator Lights 350 can include a power button for powering the device on and off, and a button which pauses operation to allow a user to perform device maintenance or remove the mixing chamber.

[0062] Fig. IB is a block diagram showing physical components of a fermentation and mixing chamber assembly of a device of the invention. The mixing chamber assembly includes mixing chamber 3, lid 25, valve assembly 11, valve spring 12, mixer 17, and valve actuator button 36. [0063] Mixing chamber 3 is a receptacle for receiving flour and water and for holding the starter. [0064] Lid 25 includes a port through which flour and water are added to the mixing chamber, and a shaft port through which the mixer shaft passes. [0065] Valve assembly 11 includes an inner valve, outer valve, and valve seal. Valve assembly 11 can be opened to allow contents of the mixing chamber to be evacuated from the bottom of the mixing chamber.

[0066] Spring 12 is operable to hold chamber valve assembly 11 in the closed position.

[0067] Mixer 17 is positioned vertically in the mixing chamber to mix the contents of the chamber.

[0068] When activated, valve actuator button 36 is operable to compress spring 12 to open valve assembly 11.

[0069] Fig. 2 is a block diagram showing input components of an embodiment of an appliance of the invention. Input components can include a flour reservoir level sensor 200, a water reservoir level sensor 210, a power button 220, a pause/resume button 230, a waste chamber present sensor 240, an ambient temperature sensor 250, a network interface 500, a mixing chamber level/overflow sensor 260, a mixing chamber present sensor 270, a chamber button actuator position sensor 280, and an ambient humidity sensor 290. Such sensors can be located at any suitable position on the device to achieve their intended purpose. For example, a flour reservoir level sensor could be located in or around the flour reservoir to detect the level of flour in the reservoir.

[0070] Fig. 3 is a block diagram showing output components for an embodiment of a device of the invention. Output components can include a mixer motor 52, visual display 6, network interface 500, mixing chamber button actuator 36, indicator LED lights 350, audible alarm 310, and flour auger motor 54.

[0071] Fig. 4 is a block diagram showing functions that may be performed by an embodiment of a device of the invention using a software application. Functions that may be performed include viewing active fault and warning messages 400, setup or modify the device’s network connection 405, restart the device’s computing systems 410, pause or resume device operation 415, view device usage and maintenance instructions 420, view current feeding schedule saved in the device’s memory 425, create new feeding schedules 430, modify or delete existing feeding schedule(s) 435, replace the active feeding schedule saved in memory 440, view device logs and history 445, view select sensor readings 450, silence audible alarms 455, reset feeding schedule to default values 460, download feeding schedules from a server 465, manually trigger select device functions to run 470, contact customer support 475, access an online storefront 480, and enable, disable, and modify notification settings 485.

[0072] Fig. 5 is a block diagram showing an exemplar sourdough feeding schedule data structure including feeding frequency 501, amount of starter to remove 502, type of feeding (grow or maintain starter volume) 503, time to run mixer motor 504, flour quantity to be transferred to the mixing chamber (time to run flour auger) 505, and water quantity to be transferred to the mixing chamber (time to run water pump) 506. These parameters may be programmatically determined and/or may be determined/influenced by the user

[0073] Fig. 6 is a flowchart 800 illustrating a method of preparing a device of the invention for standard operation. At step 810 the mixing chamber valve actuator is fully retracted into the housing base, and the mixer interlocking mechanism is set in the open position. At step 820 the mixing chamber is inserted into the housing base, and at step 830 the mixer interlocking component is pressed down into the closed position to connect the mixer motor’s shaft to the shaft of the mixer. At step 840 the user removes the flour reservoir lid and, if needed, fills the reservoir with flour; similarly, if needed the user fills the water reservoir with water. At steps 850 and 860, after powering on the appliance, the computing device checks inputs to ensure that necessary components are in the correct state for operation. At step 870, the user presses the appropriate button to send an input to the computing device to begin/resume operation according to a recipe and/or schedule which may be stored in device memory.

[0074] Fig. 7 is a flowchart 900 illustrating use of a device of the invention in the preparation of sourdough. At step 910, the user stops the device from running by pressing the appropriate button or by opening the mixer interlocking mechanism. The computing device detects this in real time and stops all operations. At step 920 the user removes the mixing chamber from its fixture in the housing base. In step 930, the user presses the valve actuator button on the mixing chamber to open the valve in the bottom of the chamber to release sourdough starter. The user then releases the valve actuator button to close the valve and stop the flow of starter. In step 940, the user places the mixing chamber back into the housing base and presses the mixer interlocking button to reconnect the mixer motor shaft to the mixer. In step 950 the computing device receives an input in real time from sensors inside the device. If no device faults are detected for a designated period of time, the computing device resumes normal operation of the device.

[0075] Fig. 8 is a flowchart 1000 illustrating a process of emptying the waste chamber of the device. A user pulls the waste chamber from the device 1010 which stops all necessary device functions and displays an appropriate message to the user 1020. In step 1030 the user empties the contents of the waste chamber and reinserts the waster chamber into the device 1040. In step 1050 a sensor in the housing base detects that the chamber has been reinserted and the device resumes all necessary functions.

[0076] Fig. 9 is a flowchart 1100 illustrating a process for modifying sourdough feeding schedules. In step 1110, using a software application running on a smartphone or computer that is connected to the device via the device’s network interface, a user can view and modify feeding schedules stored in the device’s memory. In step 1120 the user may select an option to create a new feeding schedule, edit an existing schedule, or delete a schedule. In step 1130 the user is prompted to enter new information if editing an existing schedule, or enter a new schedule. In step 1140 the user may select which schedule is to be the active schedule to be followed by the device. [0077] Fig. 10 provides a flowchart 1200 illustrating a method for determining the operational state of the device, and communicating with the user during operation. In step 1210 sensors on the device are monitored by the computing device to determine in real time if there are any changes in comparison with values stored in memory. In step 1220, if values output by sensors indicate that normal operation cannot proceed, the device enters a faulted state where normal operation ceases. In step 1230, active fault messages or warning messages are displayed to the user. In step 1240, based on current date and time values, the computing device determines when to feed the sourdough starter. During feedings an appropriate message may be displayed to the user.

[0078] Fig. 11 provides a flowchart 1300 illustrating a method for automatically feeding a sourdough according to an embodiment of a device of the invention. In step 1310, the computing device compares the current date and time to information in the currently active feeding schedule saved in memory, and performs necessary functions at times determined by the feeding schedule program. In step 1320, if the feeding is a regular feeding to maintain starter volume, the mixing chamber button actuator is activated to open the valve at the bottom of the mixing chamber to release an amount of starter into the waste chamber in an amount determined by the feeding schedule. If the feeding is a growth feeding to increase starter volume, this step is skipped. In step 1330, the flour auger is activated to move a quantity of flour determined by the feeding schedule program from the flour reservoir into the mixing chamber through an open port in the mixing chamber’s lid. In step 1340, the water pump is activated to move a volume of water determined by the feeding schedule program from the water reservoir to the mixing chamber through the open port in the mixing chamber lid. In step 1350, the mixing motor is activated to rotate the mixer inside the mixing chamber in order to mix the existing starter with the added flour and water for a length of time determined by the feeding schedule program. In step 1360, the mixed ingredients inside the mixing chamber will begin to ferment to maintain an existing starter or become a new starter.

[0079] Figs. 12-22 show various views of an embodiment of a sour dough starter device 100 of the invention. Device 100 includes housing base 10, mixing chamber assembly 400 (Figs. 12-14), flour reservoir 1, water chamber 2, and starter waste chamber 14. Flour reservoir 1 includes a lid 15 overlaying top edge 35. [0080] Housing base 10 includes a lower recessed portion 56 which defines a space for receiving mixing chamber assembly 400. Mixing chamber assembly 400 includes mixing chamber 3 that receives flour and water from flour chamber 1 and water reservoir 2, respectively, mixer 17, which includes mixer shaft 17b and mixer blades 17a, lid 25, valve assembly 11, valve spring 12, and valve activation button 36.

[0081] Waste chamber 14 is positioned beneath a transverse platform 13 located on the lower portion of housing base 10 which provides a receptacle to receive old starter that is removed from mixing chamber 3. Waste chamber 14 may include grip depressions 50 on the outer surface thereof to facilitate removal and replacement from the device. In operation, old starter passes from chamber 3 through housing base hole 44 into waste chamber 14.

[0082] Flour is moved from flour reservoir 1 into mixing chamber 3 by activation of an augur 9 which is driven by augur motor 54. Water is transferred from water reservoir 2 to mixing chamber 3 by means of a water pump inside housing base 10. In a preferred embodiment, a microcontroller 560 or other computing device controls this process. A user can manually control or modify this process using an app or the user interface 6 on the device.

[0083] Referring now to Figs. 15-22, flour and water enter mixing chamber 3 through hole 40 in lid 25. Lid 25 further includes a central hole 42 through which mixer shaft 17b passes. Lid 25 and mixer 17 can be removed from the mixing chamber for cleaning. Mixer shaft 17b passes through lid 25 to reversibly engage with mixer interlock component 700. Mixer 17 is driven by mixer motor 52.

[0084] Mixing chamber 3 further includes a valve spring 12 that holds valve assembly 11 in the closed position. Starter can be removed from mixing chamber 3 by compressing chamber valve actuator 36, which releases spring 12 thereby opening valve assembly 11 to release starter from the bottom of the mixing chamber. Valve assembly 11 at the bottom of mixing chamber 3 is held closed by a spring 12 and opened electronically when the mixing chamber is inserted into the base of the device. The valve can be opened and closed manually when the mixing chamber is not inserted into housing base 10 of the device, or when operation is controlled manually.

[0085] In a preferred embodiment, flour reservoir 1 and water reservoir 2 include a suitable sensor, for example, an optical sensor to monitor the amount of flour and water that are present. The flour and water reservoirs can be removed for filling and cleaning. Water reservoir 2 may include a handle 46 to facilitate removal from the appliance.

[0086] Mixer 17 includes a blade portion 17a and a shaft portion 17b. The top end 17c of shaft 17b is configured to reversibly engage with the shaft of mixer motor 52, to allow easy removal of mixing chamber 3 from housing base 10. [0087] In a preferred embodiment, a device of the invention is configured for automatic operation. A user can program certain aspects of the process of starter formation and maintenance including, for example, when and how often flour and water are added to the mixing chamber, and when to activate the mixer. For this purpose, the appliance is equipped with a computing device 560, memory 610, and network interface 500 to allow communication with external devices. Computing device 560 can be programmed to automatically control delivery of water and flour to the mixing chamber 3 according to a defined schedule and/or recipe, and to automatically control the mixer to produce and/or maintain starter. In addition, an app can be downloaded onto a user device including, but not limited to, a phone, allowing the user to change relevant parameters of the operation process. The display 6, input component 540, and output component 580 allow a user to directly interact with the computing device. The input component can be a touchscreen display or mechanical buttons.

[0088] In operation of a device 100 of the invention, controlled amounts of flour and water are added together to mixing chamber 3 and then mixed according to a schedule and/or recipe. A basic schedule could include, for example, performing a cycle of removing old starter, adding fresh flour and water, and then mixing the starter every 24 hours. In a method for preparing a new starter or maintaining an existing starter, a user can adjust the timing of these steps to any desired time period. Before adding fresh ingredients to the mixing chamber, a portion of old starter is generally removed from the mixing chamber 3 into the waste chamber 14.

[0089] Fabrication and assembly of a device of the invention can be carried out according to well- known methods using any suitable material including, but not limited to, metal, plastic, glass, or rubber. Preferably, a device of the invention is constructed from plastic. Plastic parts which contact food materials are preferably food-safe plastics or have a food-safe coating. The fermentation and mixing chamber is preferably made of clear plastic or glass so that the starter can be viewed from the outside.

[0090] While certain preferred embodiments of a device and method of the present invention have been described, it should be understood that the invention is not limited to the precise form of device or material, and that changes may be made thereto without departing from the scope of the invention.