Printed chocolate structures

Abstract

A method for printing a three-dimensional crystalline structure such as a chocolate layer wherein, after printing, the material has a desired crystal structure and a plurality of non-random cavities. An embodiment can include printing a liquid first layer of material with a printer onto a second layer of material having a crystal structure. Subsequently, the printed liquid first layer is processed to solidify the first layer. During the processing of the printed liquid first layer, the second layer functions as a crystal seed layer through physical contact with the printed liquid first layer and the second layer crystallizes with the crystal structure. In some embodiments, confections may be formed from high-quality chocolate, where the confection has a reduced caloric content with acceptable mouthfeel. In other embodiments, a confection may have a previously unrealized mouthfeel and taste.

1 . A method for printing an edible confection having a three-dimensional crystalline structure, comprising:
 printing a liquid first layer of material with a printer onto a second layer of material having a crystal structure to form a plurality of walls, wherein each of the plurality of walls physically contacts the second layer of material and extends from the second layer of material at an angle;   processing the printed liquid first layer to solidify the plurality of walls; and   printing a liquid third layer of material with the printer onto the second layer of material to form a ceiling that physically contacts the plurality of walls to form a plurality of non-random cavities within the confection, wherein the ceiling comprises a surface that intersects a surface of the second layer of material at an angle.   
     
     
         2 . The method of  claim 1 , further comprising:
 cooling the liquid first layer of material prior to printing the liquid third layer;   using the second layer as a crystal seed layer during the cooling of the liquid first layer of material, wherein the first layer crystallizes with the crystal structure during cooling;   cooling the liquid third layer of material; and   using the first layer as a crystal seed layer during the cooling of the third layer of material, wherein the third layer crystallizes with the crystal structure during cooling.   
     
     
         3 . The method of  claim 1 , further comprising dispensing a filling into the plurality of non-random cavities within the confection. 
     
     
         4 . The method of  claim 1 , wherein the ceiling is a first ceiling and the method further comprising:
 dispensing a first filling into a first cavity;   dispensing a second filling that is different from the first filling into a second cavity; and   printing a second ceiling over the first cavity and the second cavity to seal the first filling into the first cavity and to seal the second filling into the second cavity.   
     
     
         5 . The method of  claim 1  wherein the first layer, the second layer, and the third layer each comprises chocolate, and the method further comprises:
 printing a plurality of chocolate first walls, wherein each first wall has a first thickness; 
 printing a plurality of chocolate second walls, wherein each second wall has a second thickness that is greater than the first thickness; 
 printing a plurality of chocolate ceilings, wherein at least one of the plurality of chocolate ceilings contacts the plurality of chocolate first walls and at least one of the plurality of chocolate ceilings contacts the plurality of chocolate second walls, 
 wherein the plurality of first walls, the plurality of second walls, and the plurality of ceilings form the plurality of non-random cavities within the confection. 
 
     
     
         6 . The method of  claim 5 , further comprising forming an outer shell that seals the plurality of cavities within the confection. 
     
     
         7 . The method of  claim 6 , wherein subsequent to the formation of the outer shell, the plurality of cavities do not include a solid or a liquid filling and remain filled only with gas. 
     
     
         8 . The method of  claim 1 , further comprising:
 filling the plurality of cavities with a gas comprising at least one of methyl butanoate, ethyl butanoate, methyl hexanoate, ethyl hexanoate, β-damascenone, 2-furfurylthiol, 2-isobutyl-3-methoxypyrazine, guaiacol, 2,3-butanedione, 4-hydroxy-2,5-dimethyl-3(2H)-furanone, and combinations thereof; and   forming an outer shell that seals the gas within the plurality of cavities within the confection.   
     
     
         9 . The method of  claim 1 , further comprising:
 printing the liquid first layer of material using a drop-on-demand printer; and   printing the liquid third layer of material using the drop-on-demand printer.   
     
     
         10 . The method of  claim 1 , further comprising:
 printing the liquid first layer of material using an extrusion printer; and   printing the liquid third layer of material using the extrusion printer.   
     
     
         11 . A confection, comprising:
 a plurality of chocolate walls, wherein each chocolate wall has a thickness of between 5 micrometers and 10 millimeters;   a plurality of non-random cavities formed at least partly by the plurality of chocolate walls; and   an outer shell that seals the plurality of non-random cavities within the confection.   
     
     
         12 . The confection of  claim 11 , further comprising a plurality of chocolate ceilings that intersect the plurality of walls to provide a plurality of non-random cavities, wherein each chocolate ceiling has a thickness of between 5 micrometers and 10 millimeters. 
     
     
         13 . The confection of  claim 12 , further comprising a filling that at least partially fills the plurality of cavities. 
     
     
         14 . The confection of  claim 12 , wherein the plurality of cavities is a first plurality of cavities and the confection further comprises:
 a second plurality of cavities;   a first filling that at least partially fills, and is sealed within, the first plurality of cavities; and   a second filling that at least partially fills, and is sealed within, the second plurality of cavities, wherein the first filling is different from the second filling.   
     
     
         15 . The confection of  claim 12 , wherein the plurality of chocolate walls is a first plurality of chocolate walls having a first thickness, and the confection further comprises a second plurality of chocolate walls having a second thickness, wherein the second thickness is greater than the first thickness. 
     
     
         16 . The confection of  claim 12 , wherein:
 the plurality of walls is a first plurality of walls;   the plurality of non-random cavities is a first plurality of non-random cavities having a first width;   the first plurality of walls and the first plurality of non-random cavities provide a first confection layer;   the confection further comprises:
 a second plurality of walls; 
 a second plurality of non-random cavities having a second width that is different from the first width; 
 the second plurality of walls and the second plurality of non-random cavities provide a second confection layer. 
   
     
     
         17 . The confection of  claim 16 , wherein:
 the plurality of first walls has a first thickness;   the plurality of second walls has a second thickness; and   the first thickness is different than the second thickness.   
     
     
         18 . The confection of  claim 17 , further comprising a ceiling that separates the first confection layer from the second confection layer. 
     
     
         19 . The confection of  claim 11 , further comprising a floor that contacts the outer shell and seals the plurality of non-random cavities within the confection, wherein:
 the plurality of chocolate walls extend from the floor to the outer shell; and   each cavity connects to both the floor and the outer shell within the confection.   
     
     
         20 . The confection of  claim 11 , further comprising:
 a gas within the plurality of non-random cavities, wherein the gas comprises at least one of methyl butanoate, ethyl butanoate, methyl hexanoate, ethyl hexanoate, β-damascenone, 2-furfurylthiol, 2-isobutyl-3-methoxypyrazine, guaiacol, 2,3-butanedione, 4-hydroxy-2,5-dimethyl-3(2H)-furanone, and combinations thereof.