U.S. patent application number 10/331031 was filed with the patent office on 2003-05-15 for method and apparatus for making commercial crustless sandwiches and the crustless sandwich made thereby.
This patent application is currently assigned to The J.M. Smucker Company, an Ohio corporation. Invention is credited to Eberhart, Duane Nathan, Valenzky, Robert John JR..
Application Number | 20030091699 10/331031 |
Document ID | / |
Family ID | 25171157 |
Filed Date | 2003-05-15 |
United States Patent
Application |
20030091699 |
Kind Code |
A1 |
Valenzky, Robert John JR. ;
et al. |
May 15, 2003 |
Method and apparatus for making commercial crustless sandwiches and
the crustless sandwich made thereby
Abstract
A method of making a crustless sandwich from two slices of bread
with outer crusts, the method comprising: placing a first slice of
bread on a platen; forming a mass of a first food spread onto the
central portion of the first slice of bread in a position spaced
inwardly from a marginal area where the mass is formed with an
inner lower layer with an outer rim extending upwardly from the
lower layer to define a closed pocket or receptacle recess in the
mass; placing a second food spread in the receptacle recess;
closing the receptacle recess with a layer of the first food spread
generally coextensive with the mass and supported on the outer rim
of the mass to encapsulate the second food spread into a center
composite food layer; placing a second slice of bread over the
first slice to cover the center composite food layer; cutting the
bread slices in unison in a cut pattern to remove the crusts of the
slices; and, pressing the two bread slices together by force
through the slices against a pressure surface on the platen to
crimp the slices into a crustless sandwich.
Inventors: |
Valenzky, Robert John JR.;
(Akron, OH) ; Eberhart, Duane Nathan; (Wooster,
OH) |
Correspondence
Address: |
ROBERT V. VICKERS
FAY, SHARPE, FAGAN, MINNICH & McKEE
Seventh Floor
1100 Superior Avenue
Cleveland
OH
44114-2579
US
|
Assignee: |
The J.M. Smucker Company, an Ohio
corporation
|
Family ID: |
25171157 |
Appl. No.: |
10/331031 |
Filed: |
December 27, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10331031 |
Dec 27, 2002 |
|
|
|
09797553 |
Mar 2, 2001 |
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Current U.S.
Class: |
426/94 |
Current CPC
Class: |
A21C 15/002 20130101;
A21C 15/02 20130101; A21D 13/32 20170101 |
Class at
Publication: |
426/94 |
International
Class: |
A23G 003/00 |
Claims
Having thus defined the invention, the following is claimed:
1. A method of making a crustless sandwich from two slices of bread
with outer crusts, said method comprising: (a) placing a first
slice of bread on a platen with a central portion and a pressure
surface surrounding said central portion and defining a closed
given shape: (b) forming a mass of a first food spread onto said
first slice of bread above said central portion and spaced inwardly
of said pressure surface, said mass being formed with an inner
lower layer with an outer rim extending upwardly from said lower
layer to define a closed receptacle recess in said mass; (c)
placing a second food spread in said receptacle recess; (d) closing
said receptacle recess with a layer of said first food spread
generally coextensive with said mass and supported on said outer
rim of said mass to encapsulate said second food spread into a
center composite food layer; (e) placing a second slice of said
bread over said first slice to cover said center composite food
layer; (f) cutting said bread slices in unison in a cut pattern to
remove the crusts of said slices, said pattern being outside, but
generally matching said closed given shape; and, (g) pressing the
edges of said two bread slices together by force through said
slices against said pressure surface of said platen to crimp said
slices into a crustless sandwich.
2. A method as defined in claim 1 wherein said first food spread
has a low water activity of less than about 0.60.
3. A method as defined in claim 2 wherein said second food spread
has a high water activity greater than about 0.60.
4. A method as defined in claim 1 wherein said second food spread
has a high water activity greater than about 0.60.
5. A method as defined in claim 1 wherein said cutting is by a
cutter engaging said pressure surface.
6. A method as defined in claim 4 wherein said central portion of
said platen is recessed.
7. A method as defined in claim 6 wherein said central portion is
generally concaved.
8. A method as defined in claim 2 wherein said central portion of
said platen is recessed.
9. A method as defined in claim 8 wherein said central portion is
generally concaved.
10. A method as defined in claim 1 wherein said central portion of
said platen is recessed.
11. A method as defined in claim 10 wherein said cutting is by a
cutter engaging said pressure surface.
12. A method as defined in claim 10 wherein said central portion is
generally concaved.
13. A method as defined in claim 10 wherein said first food spread
is peanut butter and said second food spread is jelly.
14. A method as defined in claim 2 wherein said first food spread
is peanut butter and said second food spread is jelly.
15. A method as defined in claim 1 wherein said first food spread
is peanut butter and said second food spread is jelly.
16. A method as defined in claim 15 wherein said cutting is by a
cutter engaging said pressure surface.
17. A method as defined in claim 13 wherein said mass is generally
circular and said outer rim is generally circular.
18. A method as defined in claim 10 wherein said mass is generally
circular and said outer rim is generally circular.
19. A method as defined in claim 8 wherein said mass is generally
circular and said outer rim is generally circular.
20. A method as defined in claim 2 wherein said mass is generally
circular and said outer rim is generally circular.
21. A method as defined in claim 1 wherein said mass is generally
circular and said outer rim is generally circular.
22. A method as defined in claim 21 wherein said cutting is by a
cutter engaging said pressure surface.
23. A method as defined in claim 13 wherein said given shape is
generally circular.
24. A method as defined in claim 10 wherein said given shape is
generally circular.
25. A method as defined in claim 8 wherein said given shape is
generally circular.
26. A method as defined in claim 2 wherein said given shape is
generally circular.
27. A method as defined in claim 1 wherein said given shape is
generally circular.
28. A method as defined in claim 27 wherein said cutting is by a
cutter engaging said pressure surface.
29. A method as defined in claim 13 wherein said pressing act is
performed by an upper pressure plate with a lower pressure surface
overlying said pressure surface of said platen.
30. A method as defined in claim 29 wherein said lower pressure
surface includes spaced projections to create depressions in at
least said second slice of bread to form spaced pressure points in
said crimped slices of bread.
31. A method as defined in claim 10 wherein said pressing act is
performed by an upper pressure plate with a lower pressure surface
overlying said pressure surface of said platen.
32. A method as defined in claim 31 wherein said lower pressure
surface includes spaced projections to create depressions in at
least said second slice of bread to form spaced pressure points in
said crimped slices of bread.
33. A method as defined in claim 8 wherein said pressing act is
performed by an upper pressure plate with a lower pressure surface
overlying said pressure surface of said platen.
34. A method as defined in claim 33 wherein said lower pressure
surface includes spaced projections to create depressions in at
least said second slice of bread to form spaced pressure points in
said crimped slices of bread.
35. A method as defined in claim 2 wherein said pressing act is
performed by an upper pressure plate with a lower pressure surface
overlying said pressure surface of said platen.
36. A method as defined in claim 35 wherein said lower pressure
surface includes spaced projections to create depressions in at
least said second slice of bread to form spaced pressure points in
said crimped slices of bread.
37. A method as defined in claim 1 wherein said pressing act is
performed by an upper pressure plate with a lower pressure surface
overlying said pressure surface of said platen.
38. A method as defined in claim 37 wherein said lower pressure
surface includes spaced projections to create depressions in at
least said second slice of bread to form spaced pressure points in
said crimped slices of bread.
39. An apparatus for making a crustless sandwich from two slices of
bread with outer crusts, said apparatus comprising: a device to
place a first slice of bread on a platen with a central portion and
pressure surface surrounding said central portion and encompassing
a closed given shape; a first dispenser to deposit a mass of a
first food spread onto said first slice of bread above said central
portion and spaced inwardly of said pressure surface, said mass
being formed with an inner lower layer with an outer rim extending
upwardly from said lower layer to define a closed receptacle recess
in said mass; a device to place a second food spread in said
receptacle recess; second dispenser to apply a layer of said first
food spread generally coextensive with said mass and supported on
said outer rim of said mass to encapsulate said second food spread
into a center composite food layer; a device to place a second
slice of said bread over said first slice to cover said center
composite food layer; a cookie type cutter to cut said bread slices
in unison in a cut pattern to remove the crusts of said slices,
said pattern being outside, but generally matching said closed
given shape; and, a pressure plate to press the edges of said two
bread slices together by force through said slices against said
pressure surface of said platen to crimp said slices into a
crustless sandwich.
40. An apparatus as defined in claim 39 wherein said cutter cuts
against said pressure surface of said platen.
41. The apparatus as defined in claim 39 wherein said central
portion of said platen is recessed.
42. An apparatus as defined in claim 41 wherein said cutter cuts
against said pressure surface of said platen.
43. The apparatus as defined in claim 39 wherein said central
portion is generally concaved.
44. An apparatus as defined in claim 43 wherein said cutter cuts
against said pressure surface of said platen.
45. A method as defined in claim 39 wherein said mass is generally
circular and said outer rim is generally circular.
46. An apparatus as defined in claim 39 wherein said given shape is
generally circular.
47. An apparatus as defined in claim 46 wherein said cutter cuts
against said pressure surface of said platen.
48. An apparatus as defined in claim 39 wherein said pressure plate
has a lower pressure surface overlying said pressure surface of
said platen.
49. An apparatus as defined in claim 48 wherein said cutter cuts
against said pressure surface of said platen.
50. An apparatus as defined in claim 48 wherein said lower pressure
surface includes spaced projections to create depressions in at
last said second slice of bread to form spaced pressure points in
said crimped slices of bread.
51. A crustless sandwich made from two slices of bread baked to
include outer crusts, said sandwich comprising: first and second
matching crustless bread pieces cut from said crusted bread slices,
said bread pieces having the same general outer shape defined by an
outer periphery with central portions surrounded by an outer
marginal area extending inwardly of its periphery, said bread
pieces being crimped together at said outer marginal areas to
provide facing bread surfaces at said central portions, and a
central composite food layer between said central portions and
spaced inwardly of said marginal areas, said composite food layer
including a mass of a first food spread, said mass having a lower
layer with an upstanding rim to define a closed receptacle recess,
said recess filled with a second food spread and covered by a layer
of said first food spread to encapsulate said second food
spread.
52. A crustless sandwich as defined in claim 51 wherein said first
food spread has a low water activity of less than about 0.60.
53. A crustless sandwich as defined in claim 52 wherein said second
food spread has a high water activity greater than about 0.60.
54. A crustless sandwich as defined in claim 51 wherein said second
food spread has a high water activity greater than about 0.60.
55. A crustless sandwich as defined in claim 54 wherein said first
food spread is peanut butter and said second food spread is
jelly.
56. A crustless sandwich as defined in claim 53 wherein said first
food spread is peanut butter and said second food spread is
jelly.
57. A crustless sandwich as defined in claim 52 wherein said first
food spread is peanut butter and said second food spread is
jelly.
58. A crustless sandwich as defined in claim 51 wherein said first
food spread is peanut butter and said second food spread is
jelly.
59. A crustless sandwich as defined in claim 58 wherein said mass
is generally circular.
60. A crustless sandwich as defined in claim 52 wherein said mass
is generally circular.
61. A crustless sandwich as defined in claim 57 wherein said mass
is generally circular.
62. A crustless sandwich as defined in claim 56 wherein said mass
is generally circular.
63. A crustless sandwich as defined in claim 51 wherein said mass
is generally circular.
64. A crustless sandwich as defined in claim 63 wherein each of
said marginal areas have a width of at least 0.10 inches.
65. A crustless sandwich as defined in claim 63 wherein said
marginal areas each have a width of at least 0.20 inches.
66. A crustless bread as defined in claim 63 wherein said crimped
marginal areas include depressions in one of said bread pieces that
form pressure points to increase the holding force of said crimped
pieces.
67. A crustless sandwich as defined in claim 66 wherein each of
said marginal areas have a width of at least 0.10 inches.
68. A crustless sandwich as defined in claim 67 wherein each of
said marginal areas have a width of at least 0.10 inches.
69. A crustless sandwich as defined in claim 58 wherein said
crimped marginal areas include depressions in one of said bread
pieces that form pressure points to increase the holding force of
said crimped pieces.
70. A crustless sandwich as defined in claim 57 wherein said
crimped marginal areas include depressions in one of said bread
pieces that form pressure points to increase the holding force of
said crimped pieces.
71. A crustless sandwich as defined in claim 56 wherein said
crimped marginal areas include depressions in one of said bread
pieces that form pressure points to increase the holding force of
said crimped pieces.
72. A crustless sandwich as defined in claim 57 wherein said
crimped marginal areas include depressions in one of said bread
pieces that form pressure points to increase the holding force of
said crimped pieces.
73. A crustless sandwich as defined in claim 72 wherein the amount
of said second food spread is at least 25% of the amount of said
first food spread.
74. A crustless sandwich as defined in claim 63 wherein said
crimped marginal areas include depressions in one of said bread
pieces that form pressure points to increase the holding force of
said crimped pieces.
75. A crustless sandwich as defined in claim 60 wherein said
crimped marginal areas include depressions in one of said bread
pieces that form pressure points to increase the holding force of
said crimped pieces.
76. A crustless sandwich as defined in claim 58 wherein said
crimped marginal areas include depressions in one of said bread
pieces that form pressure points to increase the holding force of
said crimped pieces.
77. A crustless sandwich as defined in claim 52 wherein said
crimped marginal areas include depressions in one of said bread
pieces that form pressure points to increase the holding force of
said crimped pieces.
78. A crustless sandwich as defined in claim 51 wherein said
crimped marginal areas include depressions in one of said bread
pieces that form pressure points to increase the holding force of
said crimped pieces.
79. A dispenser for depositing a jelly receiving mass of low water
activity food spread on a slice of crusted bread, said dispenser
comprising a supply of said food spread, a discharge nozzle having
an elongated leg with first and second ends and an outer large
volume dispensing opening at said second end, a pressure cylinder
to force said food spread from said nozzle as said nozzle is
rotated about an axis generally perpendicular to said bread and at
said first end whereby said nozzle deposits a circular mass with an
outer upstanding rim to define an upwardly opened receptacle for
said jelly.
80. A dispenser as defined in claim 79 wherein said discharge
nozzle is directed vertically downward toward said slice.
81. A dispenser as defined in claim 79 wherein said discharge
nozzle is directed horizontally over said slice.
82. A crustless sandwich comprised of two pieces of bread crimped
together around their respective edges, said sandwich comprising a
center composite food layer surrounded by marginal edges of said
bread pieces, said composite food layer including a first mass of a
first food spread with a formed pocket surrounded by an upstanding
rim, a quantity of a second food spread in said pocket and a layer
of said first food spread covering said second food spread and
engaging said rim to encapsulate said second food spread.
83. A crustless sandwich as defined in claim 82 wherein said first
food spread has a low water activity of less than about 0.60.
84. A crustless sandwich as defined in claim 82 wherein said second
food spread has a high water activity greater than about 0.60.
85. A crustless sandwich as defined in claim 82 wherein said first
food spread is peanut butter and said second food spread is
jelly.
86. A crustless sandwich as defined in claim 82 wherein said mass
is generally circular.
87. A crustless sandwich as defined in claim 82 wherein each of
said marginal areas have a width of at least 0.10 inches.
88. A crustless bread as defined in claim 82 wherein said crimped
marginal areas include depressions in one of said bread pieces that
form pressure points to increase the holding force of said crimped
pieces.
Description
[0001] The present invention relates to the art of mass producing
crustless sandwiches using thin slices of standard baked bread
having a crusted outer periphery.
INCORPORATION BY REFERENCE
[0002] In recent years a tremendous volume of crustless sandwiches
have been mass produced for retail distribution using a technique
disclosed in Kretchman 6,004,596. The concept involves an
encapsulated center deposited food layer surrounded by bread pieces
cut from standard baked white bread. After the pieces have been cut
with matching shapes from separate bread slices, they are crimped
together at their outer edges so the crimped area is spaced from
the center composite food layer. This produces a bread-to-bread
sealed joint around the composite food layer. The technology
disclosed in Kretchman has resulted in a commercially successful
peanut butter and jelly sandwich ideally directed toward
consumption as snacks by children and busy adults. Since the
present invention relates to an improvement over the technology
shown in Kretchman 6,004,596, the technology of this patent is
known to the trade and need not be repeated. This patent is
incorporated by reference herein as background information.
[0003] A different crustless sandwich technology is shown in
Sollerud 3,782,270 wherein the bread slices are separated by a
squeezing action and not a combined cut and then crimped process.
This squeezing action distorts the periphery of the crustless
sandwich but does not guarantee integrity between the bread slices.
Only a small squeezed seam holds the bread together. However, this
patent does disclose a nozzle for extruding two food spreads
simultaneously for forming a composite food layer, which may
intersect the peripheral portion of the bread pieces. For the
purposes of disclosing a dispensing procedure and the mechanism for
dispensing food spread between two bread slices, Sollerud is
incorporated by reference herein as background information.
BACKGROUND OF INVENTION
[0004] For many years, hors d'oeuvres and other types of crustless
sandwiches have been made by cutting pieces of baked bread into a
desired shape and placing a food substance between the two cut
pieces. Sometimes the cook manually crimped the pieces together.
Early on, this home technique involved a combined cutter device and
crimper or merely a squeezing blade, as shown in Sollerud. These
devices were used in home kitchens and did not allow optimum
formation of a seal between the two bread layers. The seal between
bread pieces is caused by the starch content of the breads. Such
hand operated processes for producing crustless sandwiches with
seal peripheries were not adapted for mass production to produce
retail volumes of crustless sandwiches that must maintain a seal
and good appearance over long times. The peripheral seal obtained
by prior procedures used in the home, restaurants and other
catering establishments did not guarantee a complete seal around
the periphery of the sandwich. The edge would "fish mouth". The
seal was unimportant. The sandwich was consumed at once. Any
imperfections were of no significance. If the bread did not hold
together, the person making the hors d'oeuvre or sandwich would
merely manually squeeze the unsealed portion. It was found that the
prior procedures resulted in the bread memory and improper seals
causing an opening of the edges of the sandwich after long storage.
In addition, internal spreads or coatings migrated to the edges to
prevent the bread-to-bread contact for good sealing integrity.
Apparently realization of the inconsistencies and the lack of an
adequate peripheral seal obtainable by manual devices for creating
crustless sandwiches, the automated process shown in Sollerud
abandoned the concept of crimping flat peripheral areas as the
bread was cut. This automatic machine merely pinched off or
squeezed bread slices until the crust was separated and hopefully
the small sealing area would hold. But, this type of process formed
a very narrow sealing area that lacked integrity and had a pressure
gradient inward of the edge. Such process was not usable technology
for mass producing crustless sandwiches for retail
distribution.
[0005] To overcome all of these disadvantages of domestic, manual
and automated techniques for producing crustless sandwiches, the
concept shown in Kretchman 6,004,596 was developed. In this
technique, the two crusted slices of bread are provided with an
inner deposit of spread leaving an outer marginal area free of
foreign substance. The stacked bread slices with a center filling
is then cut to produce matching pieces of bread surrounding the
filling. Thereafter, a flat marginal area is crimped together,
preferably using a plurality of spaced pressure points against a
flat anvil surface. In this manner, the crimping action is
optimized by being performed after the bread is cut to shape and
having a constant pressure gradient inwardly and not affected by
the cutting action. In processes where the crimping and cutting
action is done simultaneously, the quality of the crimp is
adversely affected by the cutting action. The technique shown in
Kretchman is now used for mass producing crustless sandwiches
hermetically packaged for retail distribution. The most popular of
crustless sandwiches using the Kretchman technique is a peanut
butter and jelly version wherein a layer of peanut butter is placed
on opposite sides of a layer of jelly. Of course, the term "jelly"
means any type of fruit spread, such as, without limitation, jams,
jelly and preserves. Since the viscosity of the inner layer of
jelly is substantially less than the viscosity of the peanut
butter, there is a tendency of the jelly to spread through the
surface joint of the peanut butter layers. This leaching or
spreading action can change the mouth feel of the bread pieces,
especially after long shelf storage. In addition, when combining
peanut butter and jelly, the amount of jelly is limited. The amount
of jelly is determined by the size of the sandwich and the areas of
the peanut butter encapsulating layers. It is desirable to produce
a sandwich with a greater amount of jelly; however, such increased
jelly increases the tendency of seepage of the jelly into contact
with the bread slices. These mechanical phenomena cause limitations
in the manufacturing process. Proportions of jelly and peanut
butter were not optimized. Efforts to extrude a tube of peanut
butter around a center of jelly merely increases the probability of
seepage at the two ends of the tube. In addition, such tube is
limited to the shape of the composite food layer between the bread
slices. All of these disadvantages are dictated by the technique
heretofore used to combine peanut butter and jelly into a composite
food layer or mass in the center of a crustless bread sandwich,
which bread sandwich presents technical difficulties not
experienced in the domestic use of peanut butter and jelly on two
slices of bread. Such domestic sandwiches merely involved a layer
of peanut butter covered by a layer of jelly. The ratio of jelly to
peanut butter was according to the consumer's taste. Jelly in the
bread caused no problems because of immediate consumption.
THE INVENTION
[0006] The present invention relates to a method and apparatus for
forming the center filling of a sandwich, such as a peanut butter
and jelly sandwich made under the strict constraints of the
technology necessary for making successful crustless sandwiches
that have a high quality peripheral seal. The proportion of jelly
to peanut butter is not limited by the process. The tendency of
jelly to leach from the center filling is eliminated. Consequently,
the invention is to a method and apparatus that allows mass
production of a crustless sandwich having a composite center
filling, wherein the center filling does not drastically decrease
or affect the appearance of the product during long term storage
required in retail distribution.
[0007] In accordance with the invention, there is provided a method
for making a crustless sandwich from two thin slices of freshly
baked bread having outer crust. "Thin" means less than 3/4-inch.
This method involves placing a first slice of the bread on a platen
having a center portion and a pressure surface surrounding the
central portion. This surface encompasses a closed given shape,
such as a circle or a rectangle. In practice, the pressure surface
is also the cutting surface for a knife or cutter defining the
given shape. With the first slice of bread on the platen, a mass of
a first food spread is formed onto the first slice above the center
portion of the platen and spaced inwardly from the pressure surface
of the lower support platen. The mass is formed with an inner lower
layer having an outer rim extending upwardly from the lower layer.
Consequently, the rim defines a closed receptacle or recess in the
mass of the first food spread. This first food spread is, in the
preferred embodiment, a high viscous peanut butter having a low
water activity, such as below 0.60. With this low water activity,
the peanut butter or first food spread in contact with the bread
will not cause sogginess of the bread. The method involves placing
a second food spread into the exposed receptacle or recess in the
peanut butter. In practice, this second food spread is preferably
known as "jelly." Since the jelly has a lower viscosity than the
peanut butter, it tends to flow outwardly and fill the recess;
however, the mass includes an outer rim preventing the jelly from
spreading outwardly over the edge of the peanut butter layer. In
this manner, the receptacle or recess can be as deep and as
transversely large as necessary to accommodate the desired amount
of jelly without fear of contacting the bread of the first slice
with the jelly. In accordance with the invention, this receptacle
recess with the jelly or second food spread is closed by a layer of
the first food spread or peanut butter. Thus, a covering layer of
peanut butter is placed over the recess and in contact with the
upstanding rim dividing the recess. A second layer of bread is then
placed over the capped recess forcing the upper layer of peanut
butter into sealing relationship with the upstanding rim. This
positively encapsulates the deposited jelly to produce a sealed
composite food layer, which in the preferred embodiment comprises
peanut butter and jelly as the first and second food spreads,
respectively. By encapsulating the jelly in the peanut butter, only
the low water activity peanut butter contacts the bread, thus
preventing the bread from becoming soggy. The jelly normally has a
high water activity such as greater than 0.60. Thus, contact of the
jelly with the bread would have serious implications for long
storage of the product as necessary for hermetically sealed
sandwiches stored in freezers and/or on shelves. The invention
involves a positive encapsulation of the second food spread in a
precise receptacle formed by the first food spread. In the past,
jelly was spread between larger layers of peanut butter.
Consequently, the amount of jelly was limited. This does not
necessarily give the optimum proportion. But, more jelly caused
spreading into the bread. The invention eliminates this product
limitation.
[0008] After forming the encapsulated composite food layer spaced
inwardly from the marginal areas of bread above the pressure
surface of the lower support platen, a second slice of bread is
placed over the first slice to cover the composite food layer.
Then, the bread slices are cut in unison in a cut pattern to remove
the crust from both slices. In practice, the cut of the bread is by
a knife or cutter acting against the flat surface encompassing the
pressure surface. The cut pattern is the closed given shape of the
sandwich. Thereafter, pressure is exerted around the periphery of
the cut bread pieces and against the pressure surface of the platen
to crimp the slices into a crustless sandwich at large marginal
areas. The area has a thickness greater than 0.10 inches and
preferably greater than 0.20 inches. This surface has a generally
constant pressure gradient and not the decreasing pressure gradient
of a pinch action as suggested in Sollerud 3,782,270. By first
cutting the bread and then crimping the bread at a large flat
marginal area surrounding the center filling, the crimping action
is not dependent upon the cutting action and is uniform through the
width of the marginal area. In addition, there is not squeezing or
pinching action which causes a very thin interface between the two
slices. Thus, the method of the invention involves the technique
disclosed in Kretchman 6,004,596, with the improvement of the
manner of controlling the composite food layer to allow accurate
proportions of peanut butter and jelly and prevent undesired
seepage from the composite food layer into the bread pieces. Such
seepage as experienced in the past could adversely affect certain
portions of the crimped periphery.
[0009] In accordance with another aspect of the present invention,
the central portion of the platen supporting the first spread slice
is recess. This recess is preferably a concave structure especially
when the sandwich is circular. This recess portion may be quite
shallow but allows the bread pieces to be crimped without undue
pressure on the bread in the central portion of the sandwich being
produced. The upper peripheral surface around the recess is
normally flat to define the cutting surface and the crimping
surface.
[0010] Yet another aspect of the invention is the use of a pressure
plate for the crimping action at the periphery of the previously
cut bread pieces, wherein the lower pressure surface overlies the
pressure surface of the sandwich supporting platen. In the
preferred embodiment, the lower pressure surface includes spaced
projections to create depressions in at least the top slice of
bread to form spaced pressure points in the crimped slices.
Preferably, the projections are undulations in the pressure surface
or a series of spaced rectangular projections. The pressure surface
on the platen is flat and defines the cutting surface also. In an
embodiment, the platen defines an outer edge to coact with a cutter
in a scissor cutting action.
[0011] In accordance with another aspect of the invention, the
upwardly facing pressure surface of the platen has projections,
which may or may not match the projections on the pressure plate.
Various arrangements and modifications of the pressure plate and
the pressure surface of the platen can be made to enhance the
precise crimping action between the outer flat surfaces of the
previously cut bread pieces. The cut can be like a cookie cutter
against a flat surface or by a scissor cutting action with an edge
on the platen. Thus, crimping is a separate and distinct process
which can be optimized by modifying the crimping surfaces which are
relatively broad and encompass a substantial marginal area of the
sandwich being produced. The width of the crimped marginal areas of
the bread pieces are at least 0.10 inches. In practice, the crimped
area is at least 0.20 inches in width. This gives a general
constant force gradient over the flat marginal area. This is
different from a squeezed or pinched separation seam.
[0012] In accordance with yet another aspect of the present
invention, there is provided an apparatus for making a crustless
sandwich from two slices of bread with outer crusts. This apparatus
comprises a device to place a first slice of bread on a platen with
a center portion and a pressure surface surrounding the central
portion encompassing a closed given shape. In the preferred
embodiment, the pressure surface is a flat surface against which
the cut is made to define the shape of the sandwich. A dispenser
deposits a mass of a first food spread onto the first slice of
bread above the central portion of the platen and spaced inwardly
from the pressure surface of the platen. This mass is formed from
an inner lower layer and has an outer rim with a height of at least
0.10 inches and preferably greater than 1/8-inch. The formed rim
extends upwardly from the lower layer to define a closed receptacle
recess in the mass. This is the "jelly" pocket formed in the peanut
butter. A device is then used to place a second food spread into
the receptacle recess before a second dispenser applies a layer of
the first food spread generally coextensive with the mass and
supported on the outer rim of the mass. This allows the first
spread to encapsulate the second food spread, forming a center
composite food layer. This constitutes a novel feature of the
invention. To complete the sandwich, a second bread slice is placed
over the first slice. Then, the two slices are cut into the desired
shape. The cut can be with a cookie cutter or a scissor cutter.
Thereafter, the outer periphery of the previously cut slices is
crimped at the peripheral flat marginal areas. The crimping action
is by a force gradient generally constant over the marginal areas.
This allows optimization of the crimping action as taught by
Kretchman 6,004,596.
[0013] Another aspect of the present invention is the provision of
a crustless sandwich made from two slices of bread baked to include
outer crust. The sandwich comprises first and second matching
crustless bread pieces cut from the crusted bread slices. The bread
pieces have the same general outer shape defined by an outer
periphery with central portions surrounding the flat outer marginal
areas to provide facing bread surfaces at the central portions of
the slices. A composite food layer is provided between the central
portions of the slices and is spaced inwardly from the flat
marginal areas of the slices. The composite food layer includes a
mass of a first food spread having a lower layer with an upstanding
rim to define a closed receptacle recess or pocket. In accordance
with the invention, this recess is filled with a second food
spread, such as jelly, and is covered by a layer of the first food
spread to encapsulate the second food spread. In this manner, the
desired ratio of jelly to peanut butter can be used in the
sandwich. The quantity of jelly is not limited by the quantity of
peanut butter. The jelly is held in the peanut butter that is
sealed from leaching of jelly as the crimping action takes place.
This crustless sandwich has the advantages discussed with respect
to the method of making the sandwich.
[0014] The primary object of the present invention is the provision
of a method and apparatus for making a crustless sandwich, which
method and apparatus combines the advantageous processing procedure
in Kretchman 6,004,596 with the ability to control the portions of
two food spreads between the bread pieces, where the spreads are a
composite layer in the sandwich. There is the ability to prevent
spreading of the center food spread from two encapsulating layers
of bread contacting food spread. One food spread prevents leaching
of the inner food spread under the pressure of the crimping action
or by mere migration.
[0015] Yet another object of the present invention is the provision
of a method and apparatus, as defined above, which method and
apparatus allows the positive encapsulation of jelly in peanut
butter so that jelly does not engage the bread.
[0016] Yet another object of the present invention is the provision
of a method and apparatus, as defined above, which method and
apparatus allows the optimization of the proportion of peanut
butter and jelly in a crustless sandwich, without the disadvantage
of unwanted leaching or the need to reduce the size of the flat
marginal crimping surfaces.
[0017] Still further object of the present invention is the
provision of a crustless sandwich made by the method and apparatus
of the present invention, which sandwich can be hermetically
packaged and used for retail distribution with quantity control of
the filling and prevention of unwanted contact between one food
spread, such as jelly, and the bread.
[0018] These and other objects and advantages will become apparent
from the discussion of the distinction between the invention and
the prior art and when considering the preferred embodiment as
shown in the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0019] FIG. 1 is a pictorial view partially cross-sectioned of a
crustless sandwich made with one embodiment of the invention;
[0020] FIG. 2 is a top plan view taken through the crustless
sandwich at the stage of manufacturing shown in FIG. 4 with a
cut-away view showing a portion of the lower support platen;
[0021] FIGS. 3-8 are a series of cross-sectional views at
progressive operations in the manufacturing of the crustless
sandwich using an alternative cutting action and crimping
action;
[0022] FIG. 9 is a schematic side elevational view illustrating a
dispenser for practicing the preferred embodiment of the present
invention;
[0023] FIG. 10 is an enlarged, partial pictorial view taken
generally along line 10-10 of FIG. 9 and showing the outlet nozzle
of the dispenser schematically illustrated in FIG. 9;
[0024] FIGS. 11-13 are schematic cross-sectional views illustrating
progressive stages in forming the jelly pocket using a process and
apparatus constituting an alternative embodiment of the
invention;
[0025] FIG. 14 is an enlarged partial pictorial view showing a
further outlet nozzle to dispense peanut butter when practicing the
invention;
[0026] FIG. 15 is an enlarged cross-sectional view taken generally
along line 15-15 together with an illustration of the use of this
outlet nozzle;
[0027] FIG. 16 is a top plan view showing progressive operation of
the outlet nozzle illustrated in FIGS. 14 and 15;
[0028] FIG. 17 is a cross-section of the mass of peanut butter
applied by use of the outlet nozzle shown in FIG. 14;
[0029] FIG. 18 is a cross-sectional view of the cutting method and
apparatus now preferred for completing a sandwich using the
invention; and,
[0030] FIG. 19 is a cross-sectional view of the apparatus shown in
FIG. 18 with the preferred crimping method and apparatus for
completing a sandwich formed by practicing the present
invention.
PREFERRED EMBODIMENT
[0031] Referring now to the drawings wherein the showings are for
the purpose of illustrating the preferred embodiment only and not
for the purpose of limiting same, FIG. 1 shows a crustless sandwich
S manufactured by the method and apparatus of the invention and
constituting an aspect of the invention. This sandwich has a first
piece 10 of bread cut from a crusted slice and a second piece 12 of
bread cut from a second crusted slice. These bread slices are
freshly baked and are white bread made from batter known in the art
for providing a sealing action when pressed together at an
elevational pressure. As illustrated, the sandwich is circular;
however, in accordance with the invention it can be rectangular,
triangular, oblong or other shapes without departing from the
concept of the invention. Sandwich S includes a central composite
food layer 20 interior of the flat crimped marginal areas and
formed from a first deposit 22 of the first food spread which, in
practice, is peanut butter. A second deposit 24 of this same first
food spread encapsulates a central filling of a second food spread,
which in practice is known to the consumer as "jelly"; however, the
food spreads of deposits 22, 24 and the filling 30 can be modified.
The water activity of the first food spread is low being less than
about 0.60, whereas the second food spread of the filling can have
a variety of low or high water activities. In practice, the jelly
has a water activity of greater than 0.60. These water activities
are representative in nature and are selected so that the first
food spread will not cause pieces 10, 12 to become soggy during
long term shelf storage. Since the first food spread encapsulates
filling 30, the filling can have higher water activity without
contacting the bread to cause deleterious imperfections which are
not tolerable in mass produced sandwiches for retail distribution.
Periphery 40 is the cut profile or shape for each bread piece 10,
12 and is outside the flat marginal areas 42,44. These areas have a
flat width of at least 0.10 inches and preferably 0.20 inches. The
marginal areas do not contain food spread or other substance and
constitute the crimping areas of bread-to-bread contact over a
large sealing area. In the embodiment of the invention shown in
FIG. 1, the crimping is accomplished by undulating surfaces to
provide undulations 46, 48 producing pressure points 50 that the
high points of the undulations match each other and cause high
pressure exertion at aligned locations around periphery 40 of
sandwich S. In practice, there are no undulations on the under
surface which is formed by a generally flat anvil surface. This
surface is laterally extended to give a cookie cutter surface as
shown in FIG. 18.
[0032] The acts performed to produce crustless-sandwich S are
disclosed in FIGS. 3-8. Many variations of these process operations
or acts can be used to accomplish the objective of producing a
crustless sandwich which has a flat area sealed periphery using the
disclosed technology. Features from the several apparatuses can be
combined to perform the production process of the claimed
invention. Thus, the cutting techniques and the crimping techniques
can be combined to produce a magnitude of apparatuses.
[0033] In accordance with the invention, the quantity and
proportion of filling 20 is controlled without experiencing a
squeezing of the filling into the bread or the crimped marginal
areas during assembly of the sandwich. In the illustrated
embodiment, a movable platen P is used to receive the assembled
components of the crustless sandwich. Platen P is movable to allow
each of the process acts to be performed at different locations in
an assembly line without requiring movement of the partially
assembled sandwich components. In one aspect of the invention, the
central portion 60 of platen P is recessed. Since the illustrated
embodiment is a circular sandwich, a somewhat common recess has a
concave configuration of central portion 60 as shown in the
figures. This platen also includes upwardly facing pressure surface
62 which is preferably flat as shown in FIGS. 10-13, but is
illustrated for completeness as including an alternative surface.
As shown in FIGS. 18 and 19, the preferred flat crimping support
surface extends laterally to define the cutting surface of a cookie
cutter. All of these concepts are used in appropriate combination
to practice the invention. In the alternative concept, undulations
are on the pressure surface. The undulations define high points 62a
and low points 62b to give spaced projections formed by the high
points 62a. As shown in FIG. 3, a first slice of bread 70 having a
thickness of less than 3/4-inch and an outer crust 72 is placed
over platen P and aligned with central portion 60 so that pressure
surface 62 is within the crust, as best shown in FIG. 2. The bread
slices are preferably in the range of 1/2-3/4 inch in thickness to
control the bread component of the sandwich. A formed mass 80 of a
first food spread, preferably peanut butter, produces the first
deposit 22 of composite food layer 20. This formed mass includes a
thin inner lower layer 82 with a thickness to assure no lower holes
and a peripherally extending rim 84 to define a central filling
receiving receptacle, pocket, or cavity R. The rim has a height of
at least 0.10 inch and preferably at least 1/8-inch. The volume of
receptacle R is controlled by the exposed area of thin lower layer
82 and the extended height of peripheral rim 84. Consequently, the
volume of the receptacle is controlled to receive the desired
amount of filling 30 as shown in FIG. 4. In this manner, larger
proportions of jelly to peanut butter can be provided in sandwich S
without risking jelly to bread contact and its long term
deleterious effect. FIG. 2 is a cross section of the assembled
sandwich as it has progressed to the operation illustrated in FIG.
4. Thereafter, the inventive aspect of the present invention is
completed by the operation as illustrated in FIG. 5 wherein upper
layer or cap 90 is deposited to cover filling 30 and close
receptacle R by overlying rim 84. This produces a second deposition
24 of composite food layer 20. Layer 90 has outer edge 92 to cover
receptacle R. The edge has a shape determined by the shape of
receptacle R which, in the preferred embodiment is circular, to
encapsulate filling 30 in receptacle R. Thereafter, sandwich S is
processed in accordance with the technology described in Kretchman
6,004,596. This apparatus and process is best shown in FIGS. 18 and
19. Certain modifications of the apparatus and method in the
Kretchman patent are shown in FIGS. 1-8. However, these
modifications are not essential to the operation of the invention.
The invention involves forming central composite food layer 20 in a
crustless sandwich. The several devices and apparatuses featured
are for technical completeness.
[0034] The invention is the concept of providing the centrally
located composite food layer 20 inboard of the flat crimping
marginal areas of pieces 10, 12 by using a formed layer of a
consistent first food spread to provide a formed lower structure
capable of maintaining a receptacle R for receiving and containing
filling 30 for subsequent encapsulation by upper layer 90. The
second thin slice 100 of a bread having an outer crust 102 is
placed in general alignment with slice 70 over composite food layer
20, which in turn is aligned with recess 60 and spaced inwardly
from pressure surface 62. This process is shown in FIG. 6, but
could be done by several apparatuses and methods. Pressure surface
62 is generally aligned with marginal areas 42, 44 of the slices of
crusted bread. In FIG. 7, slices 70, 100 are cut in unison to
produce the matching pieces 10, 12 with a diameter e. Cutting is
preferable as shown in FIG. 18. The unison cutting assures that the
pieces match in shape and remain aligned on platen P. The shape of
periphery 40 is determined by knife or cutter 110 coacting in a
scissor action with cutting surface 122 of platen P for providing
the crustless sandwich with outer marginal areas not yet joined.
This scissor action is an alternative to the preferred cookie
cutter type cutting shown in FIG. 18. The marginal areas 42, 44
have a width determined by surface 62. In practice, this width is
at least 0.10 inch and in the general range of 0.20-0.50 inches. In
FIG. 8, a crimper 120 which is a cylinder in the preferred
embodiment is normally slidably received in cutter 110; however, it
can be separate from the cutter. By reciprocating crimper 120 in
cutter 110, the shape of periphery is closely matched with the
crimping action of crimper 120. The crimper includes cylindrical
wall 122 having a lower surface 124 which could be flat as shown in
FIGS. 11-13. This flat wall has protrusions to create pressure
points. It acts against a lower flat wall, preferably without
protrusions and with a lateral position as shown in FIGS. 18-19. An
upper flat surface without undulations is preferred when low
support surface 62 has undulations. If surface 62 is flat, which is
normal, then preferably the lower surface 124 has spaced
projections illustrated as alternating undulations with high points
and low points. If both the pressure surface 62 and lower crimping
surface 124 are undulating, it is preferred that the high points of
the undulations match to produce the configuration shown
schematically in FIG. 1. In practice, spaced high pressure points
are used to assure a positive crimping interaction between the
slices 10, 12. Various projections and combinations of projections
can be used for this purpose. In practice, the projections shown in
Kretchman 6,004,596 are employed with the projections being spaced
inwardly from periphery 40 to create high pressure points spaced
inward from the outer periphery 40 a small distance. In practice,
this inward spacing distance is approximately {fraction (1/16)}-1/8
inches. The pressure points could extend to periphery 40; however,
they are preferably spaced inwardly. Crimper 120 as shown in FIG. 8
matches the pressure surface 62 to crimp marginal areas 42, 44 at
locations outward from the central composite food layer 20.
[0035] A variety of dispensers could be used for depositing formed
mass 80 onto slice 70 to provide an upwardly facing receptacle R.
One embodiment is illustrated in FIGS. 9 and 10 showing dispenser
system 200 having a hopper 202 for receiving peanut butter having a
viscosity in the general range of 4000-10000 centipoise and
preferably above 6000 centipoise. The peanut butter has a water
activity less than about 0.60 to prevent water leaching into bread
slice 70. Hopper 202 has an outlet feed pipe 204 and is supplied
with peanut butter at inlet 206. Pump 208 forces peanut butter into
pipe 210 with outlet 212. Return line 214 includes pressure relief
valve 216 for returning peanut butter through pipe 218 back to
hopper 202. Thus, fresh pressurized peanut butter is available at
outlet 212. A dispensing feed ram unit 220 is communicated with
feed outlet 212 to receive peanut butter in sufficient quantities
to deposit the desired amount of peanut butter to form mass 80.
Piston 222 is reciprocated by drive device 224 having a stroke for
each reciprocation to deposit the desired amount of peanut butter
in mass 80. The peanut butter is directed through chute 230 into a
thin spout 240 rotated about axis a by a drive gear 242 rotated
through pinion gear 244 driven by stepping motor 246. As each slice
of bread is moved by platen P under dispenser system 200, step
motor 246 rotates thin outwardly extending spout 240 through an
angle of over 360.degree.. In practice, the rotation is through an
angle of 370.degree.. Axis a is generally centered with respect to
pressure surface 62 of platen P. During this rotation, piston 222
is cycled by a stroke forcing a desired amount of peanut butter
through outlet opening 250 onto slice 70. Nozzle 250 at the outlet
end of thin spout 240 has a relatively narrow leg 252 terminating
in a radially outward large volume dispensing opening 254. The
trailing edge of spout 240 includes a rim shaping mouth 256
intersecting opening 254. As a large volume of peanut butter is
dispensed through opening 254, it is shaped by the contour of mouth
256 to produce rim 84 of mass 80. As drive device 224 squeezes
peanut butter though nozzle 250 the nozzle is rotated about axis a
by motor 246 through an angle of 370.degree.. Nozzle 250 of spout
240 is spaced above bread 70 a distance to clear or set the
thickness of layer 82. This is one dispensing system that can be
used in practicing the invention to produce the desired form mass
of peanut butter to receive the desired amount of jelly or filling
30 as so far described. Several arrangements can be used to provide
pressurized peanut butter at the dispensing spout. The spout can
also have many mechanical versions.
[0036] An alternative mechanism for forming mass 80 with a lower
layer 82 and rim 84 is schematically illustrated in FIGS. 11-13. A
movable platen P' includes an upwardly facing, lower flat pressure
surface 270 circumscribed by cutting edge 272. In practice, surface
270 is extended laterally to give a cutting surface as shown in
FIGS. 18 and 19. Slice 70 is deposited upon platen P' above recess
280 in a manner and for the reasons previously discussed. A
pressurized peanut butter hopper 290 similar to the hopper in FIG.
9 includes a downwardly extending feed pipe 292 directing peanut
butter to an elongated rotating spout 300. System 200 shown in FIG.
9 is a preferred system to pressurize the peanut butter. A
dispenser piston and rotating mechanism as in FIG. 9 is used, but
not shown. Spout 300 is rotated about axis b and includes two
outboard legs with thin openings extending from axis b and each
having a length of approximately 1/2 diameter c of circular deposit
310. Feed ram unit 220 forces peanut butter into the circular
deposit 310 to a depth indicated as thickness d. Thereafter, as
shown in FIG. 13, forming plug 320 is heated and rotated fairly
rapidly. The plug includes a contoured end 322 movable into deposit
310 to force the peanut butter into the upstanding rim 84 while
leaving a thin lower layer 82. This produces a jelly receptacle or
pocket R for the purposes previously described. This gives one of
several alternative procedures to produce the "jelly" pocket R.
[0037] Referring now to FIGS. 14-17 an alternative arrangement for
forming the jelly receiving mass 80 is illustrated. An outwardly
extending rotating spout 350 is similar to spout 240 in FIG. 9 and
is rotated about axis g perpendicular through the bread slice 70. A
horizontally discharging nozzle 360 is substituted for the
downwardly directed nozzle 250 best shown in FIG. 10. Nozzle 360
includes a thin leg 362 extending outwardly from axis g and
terminating in a large rim forming opening 364. Plenum chamber 370
in spout 350 is connected to chute 330 for directing peanut butter
into passage 370 where it is forced outwardly by feed ram unit 220
as spout 350 is rotated through over 360.degree.. Spout 250 is
spaced upwardly from bread 70 a distance generally matching the
thickness of layer 82. In a like manner, spout 350 is rotated above
bread 70 a distance h to allow progressive deposition of layer 82
and rim 84 with clearance of the rim, as best shown in FIG. 16.
This produces a radius portion of mass 80 shown in FIG. 17. As the
spout is rotated, the circular mass is completed. As shown in FIG.
15, the spacing h allows spout 350 ro rotate over the previously
formed portion of mass 80 at the end of the mass forming cycle. A
large variety of other forming mechanisms can be used to practice
the present invention which is directed to the formation of the
lower food layer having an upwardly opening receptacle with a
controlled volume to allow the desired quantity of an encapsulated
second food item. Thus, the desired taste characteristics are
produced in a manner heretofore unobtainable in crustless
sandwiches. If mass 80 is not circular, it is still formed with an
upper opened recess for filling 30.
[0038] As so far disclosed, the sandwich making apparatus can have
many designs. The lower pressure surface can be flat. It can extend
laterally to provide a cutting surface. It can terminate in a
scissor cutting edge. The flat surface encompasses the marginal
crimping areas of the bread pieces. In practice, the apparatuses
shown in FIGS. 18 and 19 are preferred to make the sandwich around
central composite layer 20. Assembled bread slices and central
layer 20 as shown in FIG. 7, irrespective of the process to obtain
layer 20, is supported on platen P" with pressure surface 400 large
enough to match or encompass the marginal crimping areas of the
final sandwich S. The surface also extends outward to give a
cutting surface for knife or cutter 402 moved vertically by
pneumatic cylinder 410 to cut the bread slices 70, 100 into the
desired shape. An internal crimper 420 in the form of a crimping
die with projections 422 is moved vertically by pneumatic cylinder
424. Bottom edge 426 of crimping die 420 has a shape matching the
cut shape of cutter 402 and is spaced inwardly to give a generally
constant force gradient over the marginal areas of the slices cut
to form sandwich S. The cutting action is first and separate from
the crimping action.
[0039] The sandwich is formed with small forces, if any, to
compress the bread in center. When the marginal layers are crimped
together, they are joined by the sticking action experienced when
forming dough balls from fresh white bread.
* * * * *