INSULATED POCKET BUN
A pan is provided that has a male mold portion, a housing that surrounds the male mold portion, and a top portion with a wing plate that has a complimentary outer surface to the end surface of the male mold portion. The complimentary outer surface forms a more consistent thickness of a baked item. The housing has a bottom surface with an aperture in the bottom to receive the male mold portion. The bottom surface acts to eject the baked item from the pan as the male mold portion is removed from the pan. The top portion can be formed with a continuous surface or have a wing plate that is spaced from a planar portion.
This application is a divisional of U.S. patent application Ser. No. 15/245,956, filed Aug. 24, 2016, which is a Continuation-in-Part of U.S. application Ser. No. 14/152,074 filed Jan. 10, 2014, which is a divisional of U.S. application Ser. No. 13/553,868, filed Jul. 20, 2012, issued as U.S. Pat. No. 8,870,151 on Oct. 28, 2014, the disclosures of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTIONA typical sandwich is formed having a filling disposed between two pieces of bread. A hamburger is one common sandwich, with a ground beef patty, vegetables and condiments disposed between an upper and lower bun. Sometimes the bread is hinged, such as is used with a hotdog or sausage. The common failing of these types of sandwiches is that they can be difficult to eat tidily, especially when on the go—the sandwich filling can leak out of the bread while being eaten. As such an improved bun is needed for containing sandwich filling. The disclosure provided herein describes an improved pan for baking a bun suitable for use in making a variety of sandwiches (including, but not limited to, hotdogs, sausages, hamburgers, sub sandwiches, loose meat sandwiches, among many others).
SUMMARY OF THE INVENTIONThe present disclosure describes a pan for preparing an improved bun suitable for making various types of sandwiches. The pan described herein is composed of a base plate, a housing, an ejector plate, and a divider. The pan, when assembled, is shaped to form a pocket bun therein. The pan is designed to be disassembled in a way to allow ready ejection of the pocket bun from the pan.
The pan may include a single chamber for producing a single bun, or multiple chambers for producing multiple buns from a single pan. One chamber may include a single male mold for producing a bun having a single cavity, or multiple male molds for producing a bun having multiple cavities. The divider separates the chambers and may include openings to allow buns in adjacent chambers to form a baked connector therebetween for holding the buns together during packaging.
The pan of the present disclosure includes further improvements over previous pans, including providing a pan with means for ejecting deep-draw goods from the pan such as through a pneumatic system or use of ejection pins. In one configuration, the pan of the present disclosure produces a bun having a plurality of cavities, such that food stuffs are independently insertable into each cavity. In an additional configuration, the shape of either the exterior of the bun or the cavity of the bun is formed with a distinctive shape so as to provide unique brand-identifying capabilities. An optional top with a wing plate can help to form a portion of the outside to cause the bun to have a more defined outer shape and a controlled wall thickness.
A preferred embodiment of this invention has been chosen wherein:
The present disclosure describes a pan 10 suitable for preparing a pocket bun 12. Pocket bun 12 is a molded object one embodiment of which is shown in
As described herein, pan 10, and associated parts described in detail below, are referred to as having upper and lower ends. These designations are for ease of reference herein, with the upper end referring generally to the open top of pan 10, and the lower end referring generally to the base of pan 10 opposite the open top. It is understood that as used, pan 10 is positionable in any number of orientations, and as such any reference to upper and lower is not seen as limiting.
Pan 10 is formed from a group of nestable parts: a base plate 20, a housing 22, an ejection plate 24 and a divider 26, as shown assembled in
Housing 22, as shown in
Ejection plate 24 is defined as a generally flat plate having an outer edge 50. With pan 10 assembled, ejection plate 24 overlies lip 40 of housing 22. A notch 52 forms an indentation in edge 50, with notch 52 sized to straddle guide 42 when pan 10 is assembled, thereby notch 52 locates ejection plate 24 relative housing 22, as shown in
Divider 26 is defined as an upright plate overlying ejection plate 24 and subdividing the interior of housing 22 into multiple chambers. In the embodiments shown in
It is contemplated, such as is shown in
Referring now to
In one embodiment, a bun is formed having a pair of inner chambers. This embodiment is useful for building a three-layer sandwich, such as bun-filling-bun-filling-bun, as is common at some fast food restaurants. An example of this embodiment is shown in
One advantage of bun 12 formed by pan 10 over prior art breads is that pan 10 forms a bun where both the outer surface and the cavity surface of bun 12 has a browned surface. Most buns, for example a common hamburger bun, have a browned outer surface, but the inner surface is not browned, but is formed by splitting the bread open. The present bun 12 includes an inner cavity having a browned surface such that when a filling is placed in the bun the filling contacts a browned surface and the browned surface serves to minimize the bread becoming soggy by resisting absorption of moisture from the filling. In this way, pan 10 bakes a bun 12 which resists becoming soggy.
The outer surface of bun 12 is browned either by direct contact from heated air when baking (such as is the case at the open top of pan 10), or by conductive heat transferred from pan 10 to the bun. Base plate 20 includes apertures 28 through which heated air enters the internal cavity of male mold 30, such that male mold 30 is heated during baking so as to brown the inner cavity 16 of bun 12. Browning the inner cavity 16 of bun 12 provides the beneficial effect of forming a filling-accepting portion of bun 12 which is resistant to becoming soggy.
Pan 10 is formed from a material sufficient at least to withstand the heat of baking, to retain shape when baking, and to transfer heat to brown bun 12 when baking. Such materials include, but are not limited to, aluminum, steel and other metals, silicone, tempered glass, ceramic, or composite. Any of such materials may include a non-stick coating. Pan 10 is formed having an open top wherein the open top allow gases to escape from the pan when bun is being baked.
An embodiment of the pan 80 is shown in
The base plate 82 has the male mold portion 84 that extends from a planar portion 96. The male mold portion 84 and planar portion 96 form a continuous surface, shown in
The housing 86 has a continuous upstanding wall 100 with a top edge 102 and a bottom wall 104 with the aperture 90. The top edge 102 is shown as a smooth continuous edge. The bottom wall 104 is continuously attached where it intersects the upstanding wall 100. As previously described, the bottom wall 104 has an aperture 90 that is sized to receive the male mold portion 84. The size and shape of the aperture 90 closely match the male mold portion 84 when the base plate 82 is mated with the housing 86. Matching the sizes closely between the aperture 90 and the male mold portion 84 allow dough to be inserted into the mold without dangers of leakage as the dough is baked. The upstanding wall has an inside surface 106 and an outside surface 108. The housing 86 further includes ejection tabs 120. The ejection tabs 120 allow automation equipment to grasp the housing 86 to allow baked bread to be ejected. The ejection tabs 120 are shown as extending outwardly from the outer surface of the continuous upstanding wall 100 but other devices or features that allow for ejection are contemplated. Further, it is contemplated that the housing 86 is formed from two or more parts that would separate to allow baked bread to be more easily removed from the pan 80. A housing 86 with the ability to separate would also allow more complex shapes of bread to be baked without concern of removing baked bread from the pan 80. The housing 86 may have a tapered portion adjacent the top edge 102 to allow positioning error without mechanical interference when the top cap 92 is inserted. The distance between the top edge and the bottom wall is greater than the distance between the terminal end surface 98 and the planar portion 96. When inserted into the housing 86, the terminal end surface 98 is below the top edge 102.
The top cap 92 has a planar portion 122 and the wing plate 94, as in
Because some dough is more viscous than other dough, a stuffing ram 150, as in
To make baked bread with the pan 80, the user starts with a clean housing 86 and inserts the base plate 82 into the aperture 90. Dough 78 is then dispensed above the open top 88, where it drops onto the male mold portion, typically the terminal end surface 96. The dough 78 may fill in the voids near the bottom wall 104, based on the size of the mold and viscosity of the dough 78. At that point, the optional stuffing ram 150 is inserted, driving the dough 78 downwardly. This step is shown in
To eject the baked bread, the top cap 92 and base plate 82 are removed from the housing 86. This allows the baked bread to be ejected from the housing. Once the parts are cleaned, the pan 80 is ready for another baking cycle. As is well known in the art, it is common to apply a non-stick coating or surface on any part that may contact a food product, particularly one that is baked.
It is understood that while certain aspects of the disclosed subject matter have been shown and described, the disclosed subject matter is not limited thereto and encompasses various other embodiments and aspects. No specific limitation with respect to the specific embodiments disclosed herein is intended or should be inferred. Modifications may be made to the disclosed subject matter as set forth in the following claims.
Claims
1. A pan adapted for baking bread comprising:
- a base plate having a planar portion and a male mold portion extending therefrom to form a continuous surface, said male mold portion terminating at a terminal end surface, said terminal end surface spaced from said planar portion by a first distance, said male mold portion having draft that narrows said male mold portion with increasing distance from said base plate, said male mold portion having a perimeter defined by the intersection of said male mold and said planar portion;
- a housing having a continuous upstanding perimeter wall intersecting a bottom wall affixed thereto, said upstanding perimeter wall having an interior surface and an exterior surface, said upstanding perimeter wall having a top edge opposite said bottom wall, said top edge spaced from said bottom wall by a second distance, said bottom wall having an upper surface, a lower surface, and an aperture extending between said upper and lower surfaces adapted for receiving said male mold portion, said aperture having a complimentary shape to said perimeter of said male mold, said aperture adapted for receiving said male mold portion;
- a top cap having a top planar portion and a wing plate, said wing plate extending from said top planar portion, said wing plate having an outwardly facing surface with a profile being complimentary to and spaced from said terminal end surface of said male mold portion when a portion of said top planar portion is contacting said top edge of said housing and said wing plate extends into said housing toward said male mold portion; and
- said base plate, said housing, and said top cap forming a substantially enclosed volume when said housing receives said base plate and said top cap.
2. The pan of claim 1, wherein a portion of said outwardly facing surface being obliquely angled with respect to said top planar portion, said outwardly facing surface terminating at a perimeter edge for complimentarily contacting said interior surface of said upstanding perimeter wall.
3. The pan of claim 1, wherein said base plate having an ejection tab affixed to said planar portion, said ejection tab having a perpendicular portion extending substantially perpendicular from said planar portion to an overhanging portion, said overhanging portion being substantially parallel to said base plate.
4. The pan of claim 1, wherein said housing having an ejection tab extending outwardly from said perimeter wall.
5. The pan of claim 1, wherein said outwardly facing surface of said top cap extending outwardly from said planar portion of said top cap to form a continuous surface.
6. The pan of claim 1, further comprising a dough stuffing ram having a continuous perimeter wall adapted to encompass said male mold portion, said continuous perimeter wall having a length greater than said first distance of said base plate.
7. A pan adapted for baking bread comprising:
- a base plate having a planar portion and a male mold portion extending therefrom to form a continuous surface, said male mold portion terminating at a terminal end surface, said terminal end surface spaced from said planar portion by a first distance, said male mold portion having draft that narrows said male mold portion with increasing distance from said base plate, said male mold portion having a perimeter defined by the intersection of said male mold and said planar portion;
- a housing having a continuous upstanding perimeter wall intersecting a bottom wall affixed thereto, said upstanding perimeter wall having an interior surface and an exterior surface, said upstanding perimeter wall having a top edge opposite said bottom wall, said top edge spaced from said bottom wall by a second distance, said bottom wall having an upper surface, a lower surface, and an aperture extending between said upper and lower surfaces adapted for receiving said male mold portion, said aperture having a complimentary shape to said perimeter of said male mold, said aperture adapted for receiving said male mold portion;
- a top cap having a top planar portion and a wing plate, said wing plate extending from said top planar portion, said wing plate having an outwardly facing surface with a profile being complimentary to and spaced from said terminal end surface of said male mold portion when a portion of said top planar portion is contacting said top edge of said housing and said wing plate extends into said housing toward said male mold portion, said outwardly facing surface terminating at a perimeter edge, said perimeter edge sufficiently spaced from said interior surface of said upstanding perimeter wall to allow said wing plate to extend into said housing; and
- said base plate, said housing, and said top cap forming a substantially enclosed volume when said housing receives said base plate and said top cap.
8. The pan of claim 7, wherein a portion of said outwardly facing surface being obliquely angled with respect to said top planar portion.
9. The pan of claim 7, said base plate having an ejection tab affixed to said planar portion, said ejection tab having a perpendicular portion extending substantially perpendicular from said planar portion to an overhanging portion, said overhanging portion being substantially parallel to said base plate.
10. The pan of claim 7, wherein said housing having an ejection tab extending outwardly from said perimeter wall.
11. The pan of claim 7, wherein said outwardly facing surface of said top cap extending outwardly from said planar portion of said top cap to form a continuous surface.
12. The pan of claim 7, further comprising a dough stuffing ram having a continuous perimeter wall adapted to encompass said male mold portion, said continuous perimeter having a length greater than said first distance of said base plate.
Type: Application
Filed: Mar 20, 2019
Publication Date: Jul 18, 2019
Inventor: Robert Mayernick (South Bend, IN)
Application Number: 16/358,951