U.S. patent application number 09/479549 was filed with the patent office on 2003-02-20 for method to print multicolor images on edible pieces.
Invention is credited to ACKLEY, JR., E. MICHAEL, LOUDEN, SAMUEL J., SUTTLE, JAMES M., WEBSTER, MICHAEL E., WILLCOCKS, NEIL A., WOZNIAK, MICHAEL S..
Application Number | 20030035870 09/479549 |
Document ID | / |
Family ID | 23904473 |
Filed Date | 2003-02-20 |
United States Patent
Application |
20030035870 |
Kind Code |
A1 |
ACKLEY, JR., E. MICHAEL ; et
al. |
February 20, 2003 |
METHOD TO PRINT MULTICOLOR IMAGES ON EDIBLE PIECES
Abstract
Multicolor image, formed from at least two component images, are
printed on non-planar surfaces of edible pieces by maintaining
registration of the pieces from one printing station to another.
The registration is maintained by firmly securing the pieces to the
transporting surface by applying a pressure differential, by a
combination of a pressure differential with a resilient surface, or
by trapping the pieces between a retaining member and a recess
portion.
Inventors: |
ACKLEY, JR., E. MICHAEL;
(MOORESTOWN, NJ) ; LOUDEN, SAMUEL J.; (MOORESTOWN,
NJ) ; SUTTLE, JAMES M.; (STROUDSBURG, PA) ;
WEBSTER, MICHAEL E.; (BLAIRSTOWN, NJ) ; WILLCOCKS,
NEIL A.; (FLANDERS, NJ) ; WOZNIAK, MICHAEL S.;
(HACKETTSTOWN, NJ) |
Correspondence
Address: |
FITZPATRICK CELLA HARPER & SCINTO
30 ROCKEFELLER PLAZA
NEW YORK
NY
10112
US
|
Family ID: |
23904473 |
Appl. No.: |
09/479549 |
Filed: |
January 7, 2000 |
Current U.S.
Class: |
426/383 |
Current CPC
Class: |
B41J 3/407 20130101;
B41M 5/0023 20130101; B41F 17/30 20130101; A23G 3/28 20130101; B41P
2215/114 20130101; B41M 5/0076 20130101; B41J 3/40731 20200801;
B41J 2/01 20130101; B41J 11/0085 20130101; B41F 17/00 20130101;
B41F 17/36 20130101; B41J 3/4073 20130101; B41M 5/0047 20130101;
B41M 5/0088 20130101; A23G 3/54 20130101; B41P 2217/60 20130101;
B41F 17/006 20130101 |
Class at
Publication: |
426/383 |
International
Class: |
A23P 001/00 |
Claims
What is claimed:
1. A method to form multiple images in substantial registration on
shaped edible pieces, said method comprising the steps of: forming
an image on a shaped edible piece to form a printed piece at a
first printing station; transporting the printed piece to a second
printing station and maintaining a registering relationship of said
printed piece from said first printing station to said second
printing station by applying a pressure differential to a portion
of said printed piece effective to maintain said printed piece in a
set position in a transporting recess; and forming a second image
on said printed piece while maintaining said registering
relationship.
2. The method according to claim 1, wherein said transporting
recess includes a resilient portion, and said applying of a
pressure differential urges said printed piece against said
resilient portion.
3. The method according to claim 1, wherein said multiple images
are formed on at least one non-planar surface of said shaped edible
pieces.
4. The method according to claim 3, wherein said non-planar surface
of said edible piece is maintained above a transport surface at
said first and said second printing stations.
5. A method to form multiple images in substantial registration on
shaped edible pieces, said method comprising the steps of: forming
an image on a shaped edible piece to form a printed piece at a
first printing station; transporting the printed piece to a second
printing station and maintaining a registering relationship of said
printed piece from said first printing station to said second
printing station by trapping said printed piece between a portion
of a transporting recess and a retaining member; and forming a
second image on said printed piece while maintaining said
registering relationship.
6. The method according to claim 5, wherein said transporting
recess includes a resilient portion, and said trapping urges said
printed piece against said resilient portion.
7. The method according to claim 5, wherein said multiple images
are formed on at least one non-planar surface of said shaped edible
pieces.
8. The method according to claim 7, wherein said non-planar surface
of said shaped edible piece is maintained above a transport surface
at said first and said second printing stations.
9. A method to form multiple images in substantial registration on
a shaped edible piece, said method comprising the steps of:
retaining a shaped edible piece against a recess formed on a
transporting surface by applying a pressure differential to a
portion of said shaped edible piece effective to urge said shaped
edible piece against said recess; forming a first image on said
shaped edible piece to form a printed piece at a first printing
station; and forming a second image on said printed piece while
maintaining a registering relationship of said first image to said
second image.
10. The method according to claim 9, wherein said recess includes a
resilient portion, and said applying of a pressure differential
urges said edible piece against said resilient portion.
11. The method according to claim 9, wherein said multiple images
are formed on at least one non-planar surface of said shaped edible
piece.
12. The method according to claim 11, wherein said non-planar
surface of said shaped edible piece is maintained above said
transporting surface at said first and said second printing
stations.
13. A method to form multiple images in substantial registration on
a shaped edible piece, said method comprising the steps of:
trapping said shaped edible piece between a portion of a recess and
a retaining member; forming a first image on said edible piece to
form a printed piece at a first printing station; and forming a
second image on said printed piece while maintaining a registering
relationship of said first image to said second image.
14. The method according to claim 13, wherein said recess includes
a resilient portion, and said trapping urges said shaped edible
piece against said resilient portion.
15. The method according to claim 13, wherein said multiple images
are formed on at least one non-planar surface of said shaped edible
piece.
16. The method according to claim 15, wherein said non-planar
surface of said shaped edible piece is maintained above said
transporting surface at said first and said second printing
stations.
17. An apparatus for printing a multicolor image formed from at
least two component images on a multitude of shaped edible pieces,
said apparatus comprising: a first printing station effective to
print a first component image on said pieces at a first printing
position; a second printing station effective to print a subsequent
second component image on said pieces at a second printing
position; a transporting surface for moving said pieces from said
first printing position to said second printing position, wherein
said transporting surface includes a plurality of transporting
recess portions; and at least one retaining member for each
transporting recess portion effective to removably trap said pieces
in said transporting recess portions to maintain a registering
relationship of said first component image and said second
component image.
18. The apparatus according to claim 17, wherein said transporting
recess portions are adapted to position a non-planar surface of
said pieces above said transporting surface.
19. The apparatus of claim 17, further including a retaining plate,
wherein portions of said retaining plate form said retaining
members, and said retaining plate moves cooperatively with said
transporting surface to trap said pieces in said transporting
recess portions.
20. The apparatus of claim 17, wherein said transporting recess
portions each includes an opening through which said retaining
member extends to trap said pieces in said transporting recess
portions.
21. The apparatus of claim 17, wherein said transporting recess
portions each includes a resilient portion, and said retaining
member urges said pieces against said resilient portions.
22. The apparatus of claim 17, wherein said retaining member
includes a resilient portion, and said retaining member urges said
pieces against said resilient portions.
23. An edible shaped piece having a multicolor composite image
formed from at least two component images of edible printing ink
deposited on at least one non-planar surface of the edible shaped
piece.
24. The edible shaped piece according to claim 23, wherein said
edible piece is a shaped confectionery piece or pharmaceutical
capsule, tablet or caplet.
25. The edible shaped piece according to claim 23, wherein said
shaped confectionery piece has a lentil, oval or spherical
shape.
26. The edible shaped piece according to claim 23, wherein said
shaped confectionery is a sugar shell coated confectionery.
27. A method for forming a registered image on a shaped edible
piece, the method comprising: positioning a shaped edible piece
within a shaped transporting recess of a transporting surface such
that the shaped edible piece occupies a predetermined position
within the shaped transporting recess; forming a first component of
a composite image on the shaped edible piece while in the
predetermined position at a first printing station; transporting
the shaped edible piece to a second printing position, downstream
of the first printing station; applying a pressure differential to
a vacuum hole in communication with the transporting recess to
maintain the shaped edible piece in the predetermined position
within the transporting recess while the edible piece is at and
transported between the first and second positions; and forming a
second component of said composite image on the edible piece while
in the predetermined position, said first and second composite
images being substantially registered with one another.
28. The method according to claim 27, wherein positioning of the
shaped edible piece includes positioning the edible piece in the
transporting recess such that a non-planar portion of the edible
piece protrudes above the transporting surface.
29. The method according to claim 27, further comprising
positioning the vacuum hole at a deepest portion of said shaped
pocket.
30. The method according to claim 27, further comprising,
positioning the vacuum hole on a side wall of the shaped
pocket.
31. The method according to claim 27, wherein said applying said
pressure differential includes applying a first pressure
differential at said first and second printing stations and a
second pressure differential, less than the first pressure
differential, between the first and second printing stations.
32. The method according to claim 27, wherein said positioning of
said shaped piece includes laterally and longitudinally positioning
said shaped piece within said transporting recess so as to prevent
skewing and yawing.
33. An apparatus for forming a registered image on a shaped edible
piece, the apparatus comprising: a transport surface including at
least one shaped recess and a vacuum hole positioned within the
shaped recess, said edible piece being laterally, longitudinally
and rotationally positioned within the shaped recess at a
predetermined position; a first printer station at a first position
along a transport path that forms a first component image on the
shaped piece while in the predetermined position; a second printer
station downstream from the first position that forms a second
component of said composite image on the edible piece in
registration with the first component image of the composite image;
and a vacuum pump in communication with and applying a pressure
differential to the vacuum hole to maintain the edible piece in the
predetermined position within the recess while the edible piece is
at and between the first and second print stations.
34. The apparatus according to claim 33, wherein a non-planar
portion of said edible piece protrudes above the transport
surface.
35. The apparatus according to claim 33, wherein the vacuum hole is
positioned at a deepest portion of said shaped recess.
36. The apparatus according to claim 33, wherein the vacuum hole is
positioned on a side wall of the shaped recess.
37. The apparatus according to claim 33, further comprising a valve
system connected to the vacuum pump that applies a first pressure
differential at the print stations and a second pressure
differential, less that the first pressure differential, between
the print stations.
38. The apparatus according to claim 33, further comprising a
vacuum plenum system between the shaped recesses and the vacuum
pump and disposed below the transport path.
39. The apparatus according to claim 38, wherein the vacuum plenum
system includes first and second portions that extend transverse to
the transport path below the first and second print stations,
respectively, and a third portion including sub-plenums that extend
parallel to the transport path between the first and second print
stations.
40. The apparatus according to claim 39, wherein the first and
second portions of the plenum system are subject to first and
second pressure differentials and that are substantially equal, and
the third portion of the plenum system is subject to a third
pressure differential less than the first and second pressure
differentials.
41. The apparatus according to claim 39, wherein the transport
surface comprises at least one carrier bar including a row of
shaped recesses identical to said at least one shaped recess,
wherein said first and second portions or the plenum system are
dimensional to have widths substantially equal to a width of the
row of shaped recesses on the carrier bar.
42. The apparatus according to claim 41, wherein each of said
sub-plenums in said third portion of said plenum system corresponds
to one of said shaped recesses in said row.
43. The apparatus according to claim 33, wherein said transporting
recess portion includes a resilient portion.
44. The apparatus according to claim 33, wherein said apparatus
comprises a multi-lane system and total output of said apparatus is
at least 1,000 pieces per lane per hour.
45. The apparatus according to claim 33, wherein said first
printing station or said second printing station comprises an
offset printer.
46. The apparatus according to claim 33, wherein said first
printing station or said second printing station comprises an
inkjet printer.
47. A carrier bar comprising: a main body including an upper
surface and a lower surface; at least one shaped recess formed
within said main body along said upper surface, said shaped recess
including a shallow and a deep end; and at least one vacuum hole
formed in said lower surface and that communicates with said deep
end of the shaped recess.
48. The carrier bar according to claim 47, wherein said vacuum hole
is positioned at a lowermost portion of said deep end.
49. The carrier bar according to claim 47, wherein said vacuum hole
is positioned along a back side of the deep end.
50. The carrier bar according to claim 47, wherein leading and
trailing sides of the bar are provided with a tongue and a groove,
respectively.
51. The carrier bar according to claim 47, wherein leading and
trailing sides of the cattle bar have a stepped configuration.
52. The carrier bar according to claim 47, wherein the lower
surface of the carrier bar includes a mounting flange that mates
with a receiving groove of a carrier bar transport system.
53. The carrier bar according to claim 47, wherein at least two
vacuum holes are provided for each said at least one shaped
pocket.
54. The carrier bar according to claim 47, further comprising a
resilient member provided in said deep end adjacent said vacuum
hole.
55. The carrier bar according to claim 54, wherein the resilient
member is an O-ring that surrounds said vacuum hole.
56. The carrier bar according to claim 47, wherein each shaped
recess is formed at least in part by a sleeve that reciprocates in
a direction perpendicular to the upper and lower surfaces of the
carrier bar.
57. The carrier bar according, to claim 47, wherein each shaped
recess includes a porous resilient Portion.
58. The carrier bar according to claim 47, wherein each shaped
pocket includes guide-structure capable of longitudinally,
laterally and rotationally positioning articles received within the
shaped recess in a predetermined position.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method of printing images
onto edible pieces. Most preferably, this invention relates to the
method of forming multicolor images on non-planar surfaces of
confectionery and pharmaceutical pieces/tablets. The invention also
relates to an apparatus for practicing the method of the invention
and to edible shaped pieces having a multicolor registered
composite image on a non-planar surface thereof.
[0003] 2. Related Background
[0004] Many edible items ("pieces") have a sugar shell outer
coating. Such outer sugar shells serve many functions, including
preserving the inner ingredients and presenting an attractive
exterior. Further, the outer sugar shell can serve as a substrate
on which an image or design is formed. Such images or designs can
be, for example, an identifying trademark such as the "M" on
M&M's.RTM. Chocolate Candies pieces, or marks to identify the
inner ingredients in the case of drugs or dietary supplements.
[0005] Many methods are known to form a one-color design on to an
edible piece. U.S. Pat. No. 3,052,552, for example, describes a
method of printing chewing gum slabs prior to the slabs being cut
into sticks of individual gum pieces.
[0006] U.S. Pat. No. 5,834,047 describes a method of imprinting
shapes of multiple colors inside confectionery products by
partially filling and solidifying a confectionery material in a
mold, dispersing edible ink onto the solidified mixture through an
etched plate, and filling the remainder of the mold with
confectionery material.
[0007] It would be desirable to form multicolor designs on surfaces
of edible pieces, particularly non-planar surfaces, at high
production speeds. Multicolor designs are conveniently produced by
the application of a sequence of images, each image being a single
color. The cumulative effect is of a multicolor image or design.
Such multiple applications of images require that each applied
image be in registry with the previously applied images and with
any subsequently applied images to achieve the desired composite
image. Images applied out of registry will result in smearing,
skewing, overprinting, or other erroneous and faulty results.
[0008] Many multicolor printing methods are known in the graphic
arts for non-food products. These methods include relief printing,
stamp-printing, offset printing, pad printing, flexographic
printing, gravure printing, inkjet printing, and silk-screen
printing. Direct transfer of such methods to multicolor printing on
edible pieces, however, is difficult--particularly for printing
onto non-planar surfaces. The handling of edible pieces entails
different considerations from the handling of paper or polymer
sheets. Generally, edible pieces require more careful handling to
prevent damage or misshaping of the pieces. Further, handling food
generally require higher cleanliness.
[0009] Methods are known to perform multiple printing onto large
solid articles such as bottles and other storage cylinders. U.S.
Pat. No. 3,335,658 describes a machine that conveys individual
articles, on a disk or endless band, through printing stations and
drying stations that are placed at specific distance increments
that are not evenly divisible into the periphery distances of the
disk or endless band. U.S. Pat. No. 3,735,699 describes an
apparatus that applies rolling contact between an article held by a
mechanical holder and intermediate belt or rollers. The belt or
rollers transfer images onto the contacted, mechanically held
article. U.S. Pat. No. 4,519,310 describes transferring a plurality
of ink onto the outer periphery of a single ink form roller,
pressing a cylindrical container against the ink form roller, and
rotating the cylindrical container to transfer the ink images onto
the cylindrical container. The above patents are incorporated by
reference herein.
[0010] Methods are also known to form multicolor images on large
food items such as cakes and cookies. U.S. Pat. No. 4,578,273
describes a method of printing by forming a hard, nonporous icing
surface and printing one or more edible inks onto the hard surface
of the icing. Each piece is manually placed onto a moving mandrel
for printing by a pan flex printer. U.S. Pat. No. 4,670,271
describes a food imprinting cassette that transfers an edible
coloring material to food when pressure from a stylus is applied to
the flexible transfer sheet on which is the coloring material. U.S.
Pat. No. 5,534,281 describes a method of making printed foods with
a rotary printer that is synchronized with a dough-forming
apparatus such as a rotary cutter or rotary molder. U.S. Pat. No.
5,505,775 describes a cake decorating system incorporating a
traveling arm extending over the cake surface to carry a colorant
cartridge with a drop on demand colorant expulsion system under the
control of a central processor. A multiple orifice drop on demand
colorant expulsion system allows one pass three color printing. The
above patents are incorporated by reference herein.
[0011] Other methods are known to form multicolor designs onto flat
sheet surfaces of confections. International Patent Publication No.
WO 97/16075 describes multicolor printing onto flat sheets of
bubble gum situated in a recess having dimensions larger than that
of the flat sheets of bubble gum. A guide rail is used to laterally
shift the bubble gum sheets against a common side of the recess
before printing, but no means are provided to prevent longitudinal
shifting, skewing or yawing since the recesses are larger than the
bubble gum. It is indicated that a vacuum system inside the
apparatus could be used to remove excess starch that falls between
the slats of the conveyor bed and that, while dedusting, this
vacuum would help hold the gum sheets on the conveyor. However,
there is no disclosure or suggestion of a shaped pocket that
positions an edible piece in a predetermined position, both
laterally and longitudinally without skewing or yawing, and that
includes an opening in communication with a vacuum that maintains
the registration of an edible shaped piece between a first printing
station and a second printing station.
[0012] The methods presently available for printing multicolor
images onto edible pieces, and particularly onto non-planar
surfaces of edible pieces, are limited in their production rates.
Multicolor printing on individual pieces require an alignment of
each piece within the geometries of each printing step. Such
alignment is known as registration. Multicolor printing requires
registration in many directions. Further, unlike printing onto flat
planar surfaces, printing onto non-planar surfaces requires an
added registration alignment in regard to the contour of the
non-planar surface. The piece must not be allowed to rock, yaw, or
skew from one printing station to the next.
[0013] Generally, in mass production the multitude of pieces are
moved in relation to the usually stationary print station. Many
methods are known to transport pieces, as described in the above
patents. U.S. Pat. No. 5,836,243, incorporated by reference herein,
describes a pellet conveyor made up of a plurality of carrier bars
each having a surface defining a plurality of pockets. A brush is
described that facilitates seating of the pellets in the
pockets.
[0014] U.S. Pat. No. 4,671,892, incorporated by reference herein,
describes an apparatus for conveying and marking pellet-shaped
pieces by utilizing two printing heads positioned along an arcuate
transfer path about a transfer drum so as to apply single color
indicia to opposite sides of the pellets. U.S. Pat. No. 5,423,252,
incorporated by reference herein, describes a capsule or tablet
(article) printer in which a vacuum is applied below a transporting
belt to vacuum holes provided in article receiving pockets. In one
embodiment, a first printing unit 110 prints on one side of the
article, and another printing unit 110' prints on a second side of
the article. However, there is no disclosure of applying a vacuum
at and between the first and second printing units, registering the
printing between the first and second sides of the article, or of
the particular vacuum holes or carrier bars.
[0015] Most designs that incorporate component images to form, in
combination, a multicolor composite image, require registration in
many directions besides the longitudinal direction of movement of
the pieces. There must be registration transverse to the
longitudinal movement direction to prevent images being
inadvertently offset. There also must be registration in the third
coordinate orthogonal to the longitudinal movement direction and
the transverse direction. Finally, particularly important for
non-planar surfaces, there should be registration in regard to any
of three rotational orthogonal axes centered at each piece.
[0016] The above described methods generally require that the
individual pieces be mounted in a fixture or holder that
mechanically fixes each piece in registration. The manually aligned
methods are too slow for mass production rates except for food
items made at low throughput such as cakes. The above mechanical
attachment methods also require complex components that can become
misaligned, broken, or jammed at high production speeds. Further,
many food items are delicate and not amenable to such mechanical
forces that may be needed to maintain adequate registration of
printing at high production speeds.
[0017] U.S. Pat. No. 5,534,281 produces baked goods at moderate
production rates by utilizing the inherent stickiness or tackiness
of the dough, which must sufficiently adhere to the continuous web
conveyor in order to ensure no relevant movement between the dough
and the web, for proper alignment and registration with the
printing apparatus. Methods that rely on the tackiness of the
individual pieces or of the conveying belt are limited in their
production speed because the various production steps must be
carefully controlled to avoid breaking the adhesive bond between
the individual pieces and the conveying belt. Further, the
production speed is constrained by diametrically opposite
considerations with regard to the stickiness of the adhesive bond.
Higher printing speeds require higher levels of stickiness, but
higher offloading speeds require lower levels of stickiness. In
other words, higher stickiness holds the pieces in position more
firmly to allow higher throughput in printing but higher stickiness
prevents the pieces from being released quickly after their being
printed. Thus, the above methods are incapable of multicolor
printing onto surfaces of edible pieces, particularly onto
non-planar surfaces of edible pieces, at high production
speeds.
[0018] Presently, at high speed mass production, designs applied to
non-planar surfaces of edible pieces are limited to one-color
designs (or multiple independent designs that can be of different
colors, but are unrelated to each other) because it is very
difficult to apply consecutive images in registry to non-planar
surfaces of edible pieces. That is, after the application of one
image, the piece shifts or moves before the application of the next
image, thereby causing the images to be out of registry.
Accordingly, it would be desirable to provide a method to form
multiple images in registry onto surfaces of edible pieces, and
particularly onto non-planar surfaces of edible pieces, at high
production rates.
SUMMARY OF THE INVENTION
[0019] This invention prints multicolor images, formed from at
least two component images, on surfaces of edible pieces by
maintaining registration of the pieces from one printing station to
another. The registration is maintained by firmly securing the
pieces to the transporting surface by, for example, applying a
pressure differential and/or by applying a mechanical trapping of
the pieces to a transporting recess.
[0020] This invention is directed to a method to form multiple
images in substantial registration on edible pieces, by the steps
of i) forming an image on a surface of an edible piece to form a
printed piece at a first printing station, ii) transporting the
printed piece to a second printing station and maintaining a
registering relationship of the printed piece from the first
printing station to the second printing station by applying a
pressure differential to a portion of the piece effective to
maintain the printed piece in a set position in a transporting
recess; and iii) forming a second image on the printed piece while
maintaining the registering relationship. In a preferred embodiment
of this invention, the multiple images in substantial registration
are formed on at least one non-planar surface of the edible pieces.
In yet another embodiment of this invention, the printed piece is
maintained in the set position against a resilient portion of the
transporting recess.
[0021] Yet another embodiment of this invention is directed to a
method of forming multiple images in substantial registration on
edible pieces, by the steps of i) forming an image on a surface of
an edible piece to form a printed piece at a first printing
station; ii) transporting the printed piece to a second printing
station and maintaining a registering relationship of the printed
piece from the first printing station to the second printing
station, by trapping the printed piece between a portion of a
transporting recess and a retaining member; and iii) forming a
second image on the printed piece while maintaining the registering
relationship. Preferably, the printed surface of the edible piece
is non-planar.
[0022] Another embodiment of this invention includes an apparatus
for printing a multicolor image formed from at least two component
images on at least one surface of a multitude of edible pieces. The
apparatus includes a first printing station effective to print a
first component image on a surface of the pieces at a first
printing position and a second printing station effective to print
a subsequent second component image on the surface of the pieces at
a second printing position. A transporting surface moves the edible
particles from the first printing position to the second printing
position. The transporting surface includes a plurality of
transporting recess portions, each recess adapted to accept a
single edible piece. Preferably the recess portions are adapted to
receive a shaped piece having at least one non-planar surface. Each
transporting recess portion includes an opening which communicates
with a vacuum source. A reduced pressure is applied to the opening
effective to hold the piece in position to maintain a registering
relationship of the first component image and the second component
image on the surface of the piece. In a particularly preferred
embodiment each transport recess includes a resilient portion. The
resilient portion in cooperation with the reduced pressure retains
the piece in the transporting recess portion in a set position
during transport from the first printing station to the second
printing station to maintain a registering relationship of the
first component image and the second component image.
[0023] Still another embodiment of this invention includes an
apparatus for printing a multicolor image formed from at least two
component images on at least one surface of a multitude of edible
pieces that includes a first printing station effective to print a
first component image on the surface of the pieces at a first
printing position and a second printing station effective to print
a subsequent second component image on the surface of the pieces at
a second printing position. A transporting surface for moving the
edible pieces from the first printing position to the second
printing position includes a plurality of transporting recess
portions. There is at least one retaining member for each
transporting recess portion effective to removably trap the edible
piece in the transporting recess portion to maintain a registering
relationship of the first component image and the second component
image. Each transport recess portion is adapted to accept a single
edible piece, and more preferably a single edible piece having at
least one non-planar surface.
[0024] This invention is also directed to an edible shaped piece
having a multicolored composite image formed from at least two
component images of edible printing inks deposited on at least one
non-planar surface of the edible shaped piece. Particularly
preferred edible shaped pieces include shaped confectionery pieces
and pharmaceutical capsules, caplets and tablets. More preferably,
the edible pieces of this invention are lentil, oval, spherical, or
the like shaped confectionery, most preferably sugar shell coated
confectionery such as for example, M&M's.RTM. Chocolate Candies
pieces, Skittle.RTM. candies and the like.
[0025] As used herein, shaped edible piece means an edible piece
that is not substantially in the form of a sheet. Such a piece may
have planar surfaces, non-planar surfaces or a combination of
planar and non-planar surfaces. It is an object of the present
invention to include methods of handling and transporting shaped
edible pieces which present technical challenges as compared with
the handling and transporting of sheet-like pieces.
[0026] In preferred embodiments, the shaped edible pieces of the
present invention have at least one non-planar printing surface. A
non-planar surface, as used herein, is any surface having a radius
of curvature.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a schematic cross-sectional view of an embodiment
of this invention.
[0028] FIG. 2 is a schematic cross-sectional view of an embodiment
of this invention.
[0029] FIG. 3 is a cross-sectional view of an embodiment of this
invention.
[0030] FIG. 4 is a cross-sectional view of an embodiment of this
invention.
[0031] FIG. 5 is a cross-sectional view of an embodiment of this
invention.
[0032] FIG. 6 is a schematic diagram of an embodiment of this
invention having two printing stations.
[0033] FIG. 7 is a cross-sectional view of an embodiment of this
invention.
[0034] FIG. 8A is a schematic cross-sectional view of an embodiment
of this invention.
[0035] FIG. 8B is a schematic cross-sectional view of an embodiment
of this invention.
[0036] FIG. 9 is a cross-sectional view of an embodiment of this
invention.
[0037] FIG. 10 is a schematic cross-sectional view of an embodiment
of this invention.
[0038] FIG. 11A is a schematic cross-sectional view of an
embodiment of this invention.
[0039] FIG. 11B is a schematic cross-sectional view of an
embodiment of this invention.
[0040] FIG. 12 is a schematic cross-sectional view of an embodiment
of this invention.
[0041] FIG. 13 is a schematic view of an embodiment of this
invention.
[0042] FIG. 14 is a schematic view of an embodiment of this
invention.
[0043] FIG. 15 is a schematic view of an embodiment of this
invention.
[0044] FIG. 16 is a schematic side view of an embodiment of this
invention.
[0045] FIG. 17 is a schematic top view of the embodiment of this
invention illustrated in FIG. 16.
DETAILED DESCRIPTION OF THE INVENTION
[0046] The method of this invention forms composite images,
composed of at least two component images, on edible pieces by
maintaining the orientation of each piece from one printing station
to another printing station effective to substantially form each
component image in registration to each other. The registration of
each component image is maintained by causing each piece to remain
in a constant orientation with respect to the surface that
transports the pieces from printing station to printing station.
The orientation of the pieces to the transporting surface is fixed
by firmly securing each piece to a recess portion of the
transporting surface.
[0047] As described above, multicolor printing refers to the
formation of an image (a composite image), which can be, for
example, graphic, type, or mixture of type and graphic, from a
sequence of component images. Each component image can also be
graphic and/or type and each component image can be a different
color, the same color, a different hue, or a different value of a
color. Each component image can be formed for example from lines,
dots, solid colored areas, varying color density areas, or
mixtures.
[0048] Generally, as is the practice in the flat sheet printing
arts, each composite image in multicolor printing corresponds to
one "color". However, in special design circumstances, a component
image can itself be formed from more than one color. For example, a
printing station can form a component image from a inkjet head that
deposits two or more colors. Nevertheless, as used herein,
"multicolor" refers to forming component images from at least two
printing stations; the two color inkjet head example being
considered as one printing station. Thus, printing three colors by
forming two component images using two printing stations, one being
a two color inkjet head station, is contemplated by this invention.
However, it is preferred that each printing station be one color
because such single color printing allows faster production rates
than use of multiple-color printing heads.
[0049] Each component image is formed by a process referred to as
printing. Production of printed edible pieces in a typical high
speed mass production process can be described schematically by a
sequence of processes. The edible pieces may be first formed by
processes known in the art or by processes not yet developed. Then
the pieces are dispersed, generally according to a conveniently
designed plan, in order to present each piece to the printing
processes. In particular, the pieces are dispersed onto a
transporting surface that carries the pieces as they receive the
component images. Each component image is formed, at a printing
position, as the pieces pass through a printing station.
[0050] Referring to FIG. 6, an apparatus 606 of this invention is
shown schematically. A first printing station 601 and a second
printing station 602 are shown. A transporting surface 603 is shown
for moving edible pieces (not shown) from first printing station
601 to second printing station 602. First printing station 601
prints a first component image on the edible pieces at a first
printing position 604, while second printing station 602 prints a
second component image on the edible pieces at a second printing
position 605. Transporting surface 603 maintains a registering
relationship of the first component image and the second component
image. It is apparent that other printing stations can be
conveniently added to provide for more component images (more
"colors"). Further, it is apparent that the edible pieces must be
maintained in registration from first printing position 604 to
second printing position 605, although this registration may be
maintained from any point prior to first printing position 604 and
subsequent to second printing position 605, as desired.
[0051] Preferably, the first component image dries prior to
printing the second component image. Drying time and drying
conditions may be altered to suit the requirements of different
printing methods or images. Methods of altering the drying time or
drying conditions include, without limitation: changing the speed
of the conveying apparatus; changing the volume of air (or other
gases) to which the pieces are exposed during drying; changing the
condition of the air to which the pieces are exposed during drying
(for example, its relative humidity and temperature); and changing
the distance between printing stations.
[0052] Although the invention is described by at least two printing
stations and a transport surface effective to maintain the
registration of the images formed at each printing station
respectively to each other, this invention includes holding the
transport surface stationary after having the edible pieces
distributed on it while the printing stations are moved to print
the component images. Thus, the transporting surface can be, for
example, a batch processing surface having receiving recesses of
this invention for the edible pieces. After loading the recesses
with the edible pieces, the printing stations are brought to
sequentially print the component images on the edible pieces. In
addition, both the transport surface and the printing stations may
be moveable so long as a registered relationship is maintained from
the first printing position to the second printing position.
[0053] An aspect of this invention is that the pieces maintain a
fixed orientation with the transporting surface from one printing
station to another printing station in order to maintain
registration of each component image. With the pieces maintaining
an orientation with the transporting surface, the registration
would depend on the precision of the transporting surface, which is
more easily controlled than the movement of a multitude of
pieces.
[0054] Registration of a composite image formed from at least a
first component image and a second component image is generally
measured as the distance the first component image is off from its
designed placement in the composite image relative to the second
component image. It is preferable that the registration be
maintained at better than {fraction (1/64)}" (0.40 mm), more
preferably better than {fraction (10/1000)}" (0.25 mm), most
preferably better than {fraction (2/1000)}" (0.05 mm). By better
than {fraction (1/64)}" (0.40 mm), it is meant that one component
image is within {fraction (1/64)} (0.40 mm) of an inch from its
designed placement on the edible piece relative to another
component image. In the case of a skew error, the distance is
measured at the maximum displacement from the designed placement. A
determination of registration error requires printing of at least
two component images and measuring the maximum displaced distance
of one component image relative to another component image.
[0055] It is apparent that the amount of registration error that is
acceptable depends on the design and on the size of the edible
piece. The registration must be maintained to a higher standard to
form, for example, a two color whimsical face on Mini
M&M's.RTM. Chocolate Candies pieces, which are about 9.3 mm in
diameter, than to form a proportionately larger two color whimsical
face on M&M's.RTM. Peanut Candies pieces, which are about 14.4
mm in their smallest dimension.
[0056] It will be obvious to persons skilled in the art that
smaller or larger size shaped edible pieces may be used as
desired.
[0057] Referring to FIG. 13, an example of a composite image 1300
is shown formed on a lentil confectionery piece 1305. Composite
image 1300 is composed of a first component image 1302 and a second
component image 1303 printed on a background 1301. In this example,
component image 1302 is a black image while second component image
1303 is a white image.
[0058] Referring to FIG. 14, a composite image 1400 is shown formed
on a lentil confectionery piece 1405. Composite image 1400 is
composed of a component image 1402 and a second component image
1403 printed on a background 1401. In this example, component image
1402 is a black image while second component image 1403 is a white
image.
[0059] Referring to FIG. 15, a composite image 1500 is shown formed
on a lentil confectionery piece 1505. Composite image 1500 is
composed of a component image 1502 and a second component image
1503 printed on a background 1501. In this example, component image
1502 is a black image while second component image 1503 is a white
image.
[0060] It is apparent that the colors of the above component images
are determined by the edible ink that is used. It is well known in
the art which inks can be utilized to effect the desired properties
of, for example, color, hue, intensity, and opacity.
[0061] One embodiment of this invention maintains the orientation
of the edible pieces with the transporting surface by providing
recesses adapted to receive the edible pieces and firmly
maintaining the pieces in the recess by applying a reduced pressure
in an opening in the recess. Thus, the pieces are firmly secured in
the recesses by a vacuum or reduced pressure applied to the
pieces.
[0062] Another embodiment of this invention maintains the
orientation of the edible pieces with the transporting surface by
providing recesses, having resilient portions, adapted to receive
the edible pieces and firmly maintaining the pieces in the recess
by applying a reduced pressure in an opening in the recess. The
resilient portions conform to the edible piece contour. Thus, the
pieces are firmly secured in the recesses by a vacuum or reduced
pressure applied to the pieces.
[0063] The printing of each component image can be by any
convenient printing process such as, for example, offset printing,
flexographic printing, inkjet printing, or stamp pad printing.
Stamp pad printing offers a higher definition than the other
printing methods but at much reduced production rates. Offset and
flexographic printing are preferred because of their lower costs
and higher production rates. However, as described below, inkjet
printing is preferred for pieces with softer or rougher
surfaces.
[0064] The edible pieces used in the method of this invention can
be any convenient edible shaped article such as, for example,
candies, nuts, cookies, vitamin tablets, pharmaceutical tablets,
capsules, caplets, panned confectioneries, pressed confectioneries,
confectionery lentil pieces, rice, beans, pasta, pet food nuggets,
pet food biscuits, ice cream, and the like. Preferably the edible
pieces have a non-planar surface upon which the composite image is
printed.
[0065] The methods of this invention allow for the printing of
registered composite images onto edible pieces at high production
rates. It is preferred that the production rate be at least 200,000
edible pieces per hour, more preferably 400,000 edible pieces per
hour, and even more preferably 500,000 edible pieces per hour. The
production rates above are expressed in terms of total output. The
production rate may also be expressed in terms of pieces per hour
per lane, in a multi-lane machine. In a preferred embodiment, the
production rate is preferably at least 1,000 pieces per hour per
lane, more preferably greater than 10,000 pieces per hour per lane,
and most preferably greater than 50,000 pieces per hour per
lane.
[0066] In an offset printing process, the image is first formed as
an engraved negative image on an etched roll. The etched roll is
inked effective to transfer an ink positive image to a rubber roll.
The ink image is then transferred to the receiving surface by
firmly contacting the ink image to the receiving surface. When
using an offset printing process, the receiving surface of each
edible piece should be sufficiently firm (readily determined by one
in the art) to accept the printing rubber roll without damage.
Thus, for edible pieces having a soft or crumbling surface--such
as, for example, cookies, baked goods, or chocolate nuggets--it is
preferred that a hard shell such as a candy shell encase the piece.
Other edible pieces are manufactured in a very firm state and thus
can be printed by offset printing without a coating. Such edible
pieces include, for example, dry pasta, raw dry rice, dry beans,
and pharmaceutical capsules, caplets and tablets. Ice creams are
often made with a frozen coating sufficiently firm to act as a
receiving surface for offset printing.
[0067] In a stamp printing process, images are formed as a raised
surface on a stamping pad. Ink is applied to the raised surface and
the image is transferred to the receiving surface by firmly
pressing the raised surface against the receiving surface. In this
process, the receiving surface generally needs to be more firm,
readily determined by one in the art, than that firmness required
for offset printing.
[0068] In the pad printing process, similar to offset printing
process, ink is applied to a negative etched image. The inked image
is transferred in positive image form to a resilient surface print
pad that prints onto a receiving surface.
[0069] In an inkjet printing process, ink is applied as a stream of
ink particles or aerosols directly on to a receiving surface. Thus,
an image can be formed on soft or crumbling surfaces because no
contact is made other than by the jet of ink.
[0070] Nevertheless, in utilizing a vacuum or a pressure
differential to maintain the position of an edible piece with
respect to the transporting surface, the edible piece should be of
sufficiently low porosity, readily determined by one in the art, to
respond to the applied pressure differential to firmly press, set
or fix the edible piece against the transporting surface.
[0071] Referring to FIG. 1, a conveying substrate 100 is shown in
cross-section transverse to the direction of conveyance. Substrate
100 is supported on base 103. Substrate 100 includes a plurality of
recesses 101 adapted to accept edible pieces (not shown). Recess
101 includes at least one opening 102 providing communication with
at least one chamber 104. Chamber 104 contains reduced pressure
supplied by a vacuum pump (not shown) through at least one vacuum
access opening 105.
[0072] Substrate 100, ie. the transporting surface, can be composed
of any convenient suitable material such as, for example, metal,
polymer, plastic, composite, or ceramic. Substrate 100 can be any
convenient shape such as, for example, an endless belt, a disk, a
ring, or a pin bed. Substrate 100 can be formed from a plurality of
convenient elements such as, for example, flat bars, or scalloped
edged flat plates. Further, each element can include one or more
recess portions. For example, a moving substrate is described in
U.S. Pat. No. 5,433,146, incorporated herein by reference.
[0073] A seal (not shown) may be between elements to assist in
maintaining the reduced pressure in chamber 104. Such seals can be
formed, for example, by machining the elements to close mating
tolerances, by positioning gasket material between the elements, by
positioning sealing material to bridge the gap between the
elements, e.g., see FIG. 7, and by disposing a suitable liquid,
semi-liquid, or elastomeric material between the elements.
[0074] Substrate 100 can be moved by any convenient method (not
shown) well known in the art such as, for example, by stepping
motors, continuous motors, or servo controllers acting on the
substrate directly or through any of gears, pulleys, chains, or
sprockets; including as shown in U.S. Pat. No. 5,433,146.
Generally, the movement of the substrate is coordinated with the
printing stations. Such coordination (not shown) can be achieved
utilizing any convenient method such as, for example, through any
of gears, pulleys, chains or sprockets. Such coordination is
described for example, in U.S. Pat. No. 5,433,146.
[0075] Base 103 can be composed of any convenient material such as,
for example, metal, polymer, composite, or ceramic. Base 103 can be
of any convenient shape and can include one or more supports 107,
or plenum dividers, to assist in maintaining the shape of substrate
100 against the pressure differential across the substrate.
Supports 107 can optionally include one or more slide elements 108
to facilitate movement of substrate 100 relative to base 103. Slide
element 108 can conveniently be a slippery polymer such as a
polyfluorinated polymer or a nylon. Slide element can also be any
convenient mechanical element such as, for example, roller bearing,
ball bearing, oiled bronze runner, or smooth metal. Supports 107
can optionally include one or more openings 109 to facilitate
distribution of reduced pressure through chamber 104.
[0076] Optional seal 106 assists in maintaining a reduced pressure
in chamber 104. It is preferable to include seal 106 to minimize
pump capacity requirements. Seal 106 can be any convenient seal
such as, for example, a nylon portion, an interlocking geometry,
and the like. Seal 106 also serves as a sliding element.
[0077] Recess 101 can be any convenient shape effective to accept a
convenient piece substantially in a consistent orientation. Such
shapes can conveniently be in correspondence with the shape of the
edible piece to be accepted. The recesses may also be shaped so
that edible pieces may be positioned laterally, longitudinally and
rotationally within the recesses in a predetermined position, and
also aid in preventing skewing and yawing of the edible pieces.
However, recess 101 can have a shape substantially different from
the shape of the edible piece to be accepted in order to facilitate
the receiving of the edible pieces from the input feeding station
onto the substrate. Such shapes are described, for example, in U.S.
Pat. Nos. 5,433,146, 5,768,996, 5,836,243, and 5,655,453, each
incorporated by reference herein. Other examples of recesses are
shown in FIGS. 3, 4, and 5.
[0078] The recesses utilized in this invention preferably allow the
surface of the edible piece, and particularly a non-planar surface
of the edible piece, to be above the surface proximate to the
recess--that is, the printing should be performed "proud" as
opposed to printing in "relief". Thus, the depth of the recess
should be less than the thickness of the edible piece, measured
from the printing surface of the piece, in order to allow the
surface to protrude and be proud in relation to the surface
proximate to the recess. Such proud printing advantageously
presents more of the non-planar surface of the piece to the
printing process. Thus, a larger portion of the non-planar surface
of an edible piece can be printed as compared to relief printing
where the non-planar surface, or a portion thereof, of the edible
piece is below the surface proximate to the recess.
[0079] The vacuum or pressure differential can be provided by any
convenient method such as, for example, by utilizing a vacuum pump,
and a transverse airflow across the vacuum holes (the Bernoulli
effect).
[0080] FIG. 16 is an exemplary illustration of an overall conveying
system that includes an endless loop L comprising, for example, a
plurality of carrier bars attached to a chain that is entrained
about a series of sprockets S. A hopper H contains a plurality of
shaped edible pieces that are received within transporting recesses
formed in each of the carrier bars as the loop L travels along a
clockwise direction indicated by arrow A. The upper run of the loop
L includes three printing units 1-3 that print registered images on
the pieces as they pass below. After printing, the edible pieces
are dropped into a bin B.
[0081] The printing unit 3 may be formed as part of a module M that
can be readily removed from the loop L by shortening the chain and
removing a set number of carrier bars. Conversely, additional
modules M can be added by lengthening the chain and adding carrier
bars.
[0082] In a preferred embodiment of this invention, a first vacuum
pump V1 controls the pressure at and between each of the printing
units 1-3. A plenum system is provided below the printing stations
1-3. A vacuum pressure P1 is applied to first and second portions
of the plenum immediately below the first and second printing units
1, respectively. Preferably, the pressure P1 is higher than vacuum
pressure P2 applied to a third portion of the plenum system between
the first and second printing units 1 and 2. A valve system can be
used to create different pressures using a single vacuum pump. The
vacuum pressure P1 is higher than the vacuum pressure P2 because
the edible pieces tend to adhere to the printing roll of the
printing units 1 and 2. For example, the vacuum pump V1 can be a
6-8 hp motor having a capacity of 300-400 cfm, depending on the
type of piece being conveyed. The vacuum pump V2 can form a part of
the module M and may be a 5.5 hp motor having a capacity of 240
cfm, depending on the type of piece conveyed. The vacuum pump V2
may be smaller than the vacuum pump V1 because the vacuum pump V1
supplies vacuum pressure below printing units 1 and 2 as well as
between those units, whereas the vacuum pump V2 supplies vacuum
pressure only to the third printing unit 3 as well as between
printing units 2 and 3.
[0083] FIG. 17 shows an exemplary plan view of the vacuum system,
along with a carrier bar CB shown alongside. Each plenum positioned
below the printing roll of each printing unit is subject to vacuum
pressure P1 and has a width approximately equal to or less than a
width of the carrier bar CB. The plenums associated with the
printing rolls extend transverse to the traveling direction of the
loop L, column-wise in FIG. 17. By contrast, in a preferred
embodiment, a plurality of sub-plenums are positioned between the
printing units, which are subject to vacuum pressure P2, and extend
along the traveling direction of the loop L, row-wise in FIG. 17.
Preferably, a row is provided for each recess R within the carrier
bar CB. As shown in FIG. 1, adjacent row oriented plenums may
communicate with one another via holes 109 in the supports 107.
[0084] In FIG. 16, printing is performed on only one side of the
edible articles. However, printing on both sides of the edible
pieces is also within the scope of the present invention. For
example, Ackley's U.S. Pat. No. 5,878,658, incorporated by
reference, discloses a ramp feeder including a two-sided printer
for tablets and capsules that may be used with the ramp feeder
shown in FIG. 16.
[0085] In particular applications, where a pressurized processing
step may be required between applications of images, the pressure
differential can conveniently be provided by the difference between
the raised pressure and atmospheric (or lower) pressure.
Nevertheless, it is preferable to supply reduced pressure to assure
that the pieces are firmly secured to the recesses.
[0086] As described above, the action of the vacuum or pressure on
the edible pieces is formed by positioning the edible piece between
a volume of higher pressure and a volume of lower pressure
effective to firmly urge the edible piece against a transporting
surface. This pressure differential is formed by any convenient
method such as, for example, providing at least one opening in a
transporting surface effective to provide access from a volume of
higher pressure to a volume of lower pressure. By positioning an
edible piece over at least one such opening, the force arising from
the pressure differential is applied to the edible piece, urging
the piece in the recess against the transporting surface.
[0087] Printing processes that utilize contact of a printing
surface to the receiving surface subject the receiving surface to a
force that tends to urge the receiving surface towards the printing
surface as the printing surface moves away from the receiving
surface after printing. Such urging is caused by the ink that is
momentarily between the receiving surface and the printing surface,
and by the resilience of the printing surface. The ink acts as a
bonding medium between the two surfaces to urge the receiving
surface towards the printing surface; the rebound of the resilient
printing surface is transferred to the printing surface to urge the
receiving surface in the same direction as the rebounding printing
surface.
[0088] Therefore, less force is needed to maintain the position of
the edible piece while the edible piece is between printing
stations than during the printing operations at the printing
stations. Thus, one example of this invention provides added vacuum
at the printing stations 601 and 602, particularly at printing
positions 604 and 605, to minimize the reduced-pressure supply
requirements. That is, less reduced-pressure is applied to the
edible pieces when the pieces are not at the printing positions.
Such pressure allocation can be by any convenient method well known
to one in the art such as, for example, by ducting, by baffles, by
added pumps, or by volume differentiation.
[0089] The recesses can also be formed in detachable elements that
can be fixed to a transport surface. Referring to FIG. 3, an
element 300 has a recess 301 adapted to accept an edible piece 320.
At least one opening 302 provides communication to reduced pressure
provided by corresponding openings on a transport surface (not
shown). The element can be mounted to the transport surface by any
convenient method such as, for example, bolts, screws, clamps, or
adhesives.
[0090] In one example, element 300 is shown in cross-section
transverse to the longitudinal direction of transporting the pieces
to the printer. In this example, element 300 is preferably
substantially long in the direction into the paper and can be
described as a slat or bar. Element 300, when formed as a slat,
preferably contains a multitude of recesses 301. The slat can be
mounted or removed by a quick release mechanism as described in
U.S. Pat. No. 5,630,499, incorporated herein by reference. FIG. 3
shows optional mounting holes 312 through which element 300 can be
selectively attached and detached to corresponding threaded holes
in the transport surface.
[0091] Element 300 can also, in another example, be described by
FIG. 3 as a cross-section taken in the longitudinal direction of
transport. In this case, a multitude of elements 300 are preferably
mounted in a row across the transverse direction.
[0092] Referring to FIG. 4, an element 400 shown in cross-section
transverse to the longitudinal direction of travel, has a recess
401 adapted to accept an edible piece 420. At least one opening 402
provides communication to reduced pressure provided by
corresponding openings on a transport surface (not shown). Optional
mounting holes 412A and 412B allow mounting of element 400 to the
transport surface. In this case, element 400 is formed to allow
mounting hole 412A of one element 400 to overlap mounting hole 412B
of another element 400' (not shown), thereby presenting a
substantially contiguous surface having a regular distribution of
recesses 401 for situations where it is desirable to present a
planar array of edible pieces, such as in batch processes where the
printing stations are moved in relation to the array of pieces.
[0093] In situations such as, for example, an endless belt, the
overlapping geometry of the left and right sides of element 400 can
provide a seal to minimize vacuum pump requirements.
[0094] Recesses 401 are adapted to facilitate loading of pieces
420. Pieces can be dropped from a hopper and urged to the proper
position relative to the recesses. Methods to distribute pieces to
a consistent position in an array are described in U.S. Pat. Nos.
5,433,146, 5,768,996, 5,863,243, 5,655,453, and 5,630,499. Such
urging can be also include any convenient method such as by
vibrating, brushing, or by the action of a designed geometry of the
hopper and the receiving transport surface. After piece 420 is in
the proper position, vacuum is applied to firmly secure piece 420
to element 400.
[0095] Referring to FIG. 7, an element 700 shown in cross-section
transverse to the longitudinal direction of travel, has a recess
701 adapted to accept an edible piece 720. At least one opening 702
provides communication to reduced pressure provided by
corresponding openings on a transport surface (not shown). A tongue
712B mates with a groove 712A to provide vacuum seals between a
multitude of elements 700 to be arrayed on a transport surface.
Elements 700 can be affixed to transport surface by magnetic
attraction by applying a magnetic field to the transport surface
with a magnetic coil (not shown). Recess 701 has resilient portions
721, or O-rings, that assist in maintaining edible piece 720 in
position. Resilient portions 721 conform to the contour of edible
piece 720 and assist in maintaining the reduced pressure applied to
edible piece 720.
[0096] It is preferable that the openings that provide
communication to reduced pressure be positioned to urge the piece
into the proper position relative to the recess.
[0097] Recesses having resilient portions can also be formed
directly on the transport surfaces. As described above, such
resilient portions can be formed from rubber, urethane, teflon,
nylon, and the like.
[0098] In another embodiment, the edible piece is positioned in a
recess that includes a surface portion formed from a resilient
material. Referring to FIG. 2, a conveying substrate 200 is shown
in cross-section transverse to the direction of conveyance.
Substrate 200 is supported by supports 203. Similar to that of FIG.
1, supports 203 can optionally include slide elements 208.
Substrate 200 includes a plurality of recesses 201 adapted to
accept edible pieces (not shown). Recess 201 includes at least one
resilient portion 244 formed from a resilient material. Recess 201
also includes at least one opening 202 that provides communication
to a reduced pressure. In this example, a volume 224 provides
reduced pressure to opening 202. Volume 224 has a reduced pressure
that can be provided from any convenient source (not shown) such
as, for example, a rotary vacuum pump and a reciprocal vacuum
pump.
[0099] Resilient portion 244 can be formed by any convenient method
such as, for example, coating a surface portion of recess 201 with
a resilient layer. The resilient layer can be conveniently formed
from, for example, rubber, silicone, elastomer, and the like.
Resilient portion 244 can also be formed by one or more inserts 204
made from a the same or similar resilient materials as recited
above.
[0100] As with recess 101 discussed previously, recess 201 can be
any convenient shape effective to accept a convenient piece
substantially in a consistent orientation.
[0101] Referring to FIG. 5, an element 500 includes a recess 501
adapted to receive an edible piece 520. A resilient portion 502
forms a resilient surface portion of recess 501. A mounting flange
512 allows a multitude of elements to be mounted on a transport
surface 513 provided with corresponding mounting flange receiving
grooves. The elements can be fixed to the receiving grooves by set
screws or tangs (not shown). At least one opening 524B on element
500 communicates with at least one opening 524A on transport
surface 513. Reduced pressure is supplied through openings 524A and
524B to firmly maintain the position of edible piece 520 in
relation to element 500.
[0102] In another example, referring to FIG. 10, a plurality of
slat elements 1000 are shown in cross-section transverse to the
longitudinal direction of transport. Slat element 1000 has a recess
1001 adapted to receive edible piece 1020. Recess 1001 includes a
porous resilient portion 1002. Recess 1024B in communication with
opening 1024A in transport surface 1013 allows a reduced pressure
in volume 1004 to be applied to edible piece 1020 through porous
resilient portion 1002 to maintain a position of edible piece 1020
to element 1000.
[0103] As described above, the non-planar surface of the edible
piece can be positioned above the transporting surface. In one
embodiment, the piece is raised prior to printing. Referring to
FIG. 11A, an element shown, in this example transverse to the
direction of transport, includes a recess 1101 adapted to receive
an edible piece 1120. Recess 1101 includes at least one opening
adapted to embrace sleeve 1122. Sleeve 1122 includes at least one
opening 1124 to allow reduced pressure from a volume 1104 to be
applied to edible piece 1120. Sleeve 1122 moves in response to
contour or cam surface 1130.
[0104] As shown in FIG. 11B, contour surface 1130 can urge sleeve
1122 upwards to raise edible piece 1120 from the surface of element
1100. Sleeve 1122 should be prevented from pivoting by, for
example, shaping the sleeve and receiving opening appropriately
with corners, or flanges (not shown). Optionally, guides, rollers,
and slides can be provided between sleeve 1122 and contour surface
1130.
[0105] In another example, the sleeve is lowered to provide access
to the non-planar surface above the transport surface. Referring to
FIG. 12, a multitude of elements 1200 are shown in cross-section in
the longitudinal direction of transport (the pieces are moved from
left to right). Element 1200 includes a recess 1201 adapted to
receive an edible piece 1220. Recess 1201 includes at least one
opening adapted to receive a sleeve 1222. Sleeve 1222 includes at
least one opening 1224 that provides communication to a reduced
pressure in a volume 1204. The reduced pressure applied to edible
piece 1220 maintains a position of edible piece 1220 to element
1200. The action of a contour surface 1230 is shown causing sleeve
1222 to lower as the contour surface moves away from the element
1200. A seal 1206 assists in maintaining a pressure differential
across the edible piece and minimizes the capacity requirements for
the source of reduced pressure (not shown).
[0106] In yet another embodiment, the edible piece is positioned in
a recess and held in the recess mechanically by a retaining plate
or retaining fingers. Referring to FIG. 8A, a conveying substrate
800 is shown in cross-section transverse to the direction of
conveyance. FIG. 8B shows a plurality of substrates 800, 800',
800", and 800'". Substrates 800, 800', 800", and 800'" are
interconnected by hinges (not shown) to form an endless belt.
Substrate 800 is supported by supports 803. Similar to FIG. 1,
supports 803 can optionally include slide elements 808. Substrate
800 includes a plurality of recesses 801 adapted to accept edible
pieces 820. A retaining plate 830 includes a retaining member 831
that holds edible piece 820 against recess 801 in a fixed position.
Retaining plate 830 includes at least an opening 832 to allow
access to edible piece 820 by a printing station (not shown).
[0107] When retaining plate 830 is urged against edible pieces 820,
edible pieces are firmly held in position in recess 801. The urging
of plate 830 against edible pieces 820 can be by any convenient
method such as, for example, by holddown fingers 840 connected to
cam followers 841. As cam followers 841 ride over an appropriate
contour (not shown) force is applied or released to the holddown
fingers. Force is applied between printing positions effective to
maintain registration of the applied component images. Other
methods for urging plate 830 against edible pieces 820 can be, for
example, utilizing electromagnetic actuators between the retaining
plate and the transport surface, applying spring pressure between
the retaining plate and a surface above (looking at FIGS. 8A and
8B) the retaining plate, and applying a spring pressure to pull
retaining plate towards the transport surface, allowing the weight
of the retaining plate to exert against the edible pieces.
[0108] Retaining plate 830 can be any convenient shape such as, for
example, an open web, and an articulated series of plates.
Retaining plate 830 can include any convenient number of retaining
member 831. Retaining member 831 can be the inner circumferential
contour of opening 832. Retaining member 831 can be formed from a
separate material from retaining plate 830 or can be formed from a
portion of retaining plate 830. Retaining member 831 can be a
series of channels, guides, or placks situated to trap the edible
pieces against the recesses.
[0109] Optionally, recess 801 includes at least one surface portion
804 that is resilient. Resilient portion 804 assists in maintaining
the position of the edible piece in the recess by adapting to
variations in the shape of the edible piece and minimizes damage to
the edible piece by cushioning the edible piece in the recess.
[0110] The edible pieces can also be held in position by retaining
members without a retaining plate. Referring to FIG. 9, an element
900A is mounted to a transporting surface 900B. Element 900A
includes a recess 901 adapted to receive an edible piece 920. A
retaining member 931 pivots on a pivot 933 to hold edible piece 920
once edible piece is in position. Retaining member 931 is shown, in
this example, pivoting in response to an actuator 935. Other
convenient methods can be used to move the retaining member to trap
the edible piece firmly in the transporting recess such as, for
example, by electromagnetic actuators, and by a spring force
responsive to a position sensor.
[0111] Optionally, recess 901 includes portions 904A and 904C that
can be resilient, as described above for 804. Further, optionally,
retaining member 931 can also include resilient portion 904B.
[0112] The transporting surface can be held stationary in each of
the above examples while the printing stations are moved to print
the component images sequentially. Further, the printing stations
and the transporting surfaces can be all moved relative to each
other and/or relative to the earth so long as the registered
relationship of the piece is maintained.
[0113] Other variations and modifications of this invention will be
apparent to those skilled in this art after careful study of this
application. This invention is not to be limited except as set
forth in the following claims.
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