U.S. patent application number 10/643052 was filed with the patent office on 2004-02-19 for food holding cabinet assembly.
This patent application is currently assigned to Burger King Corporation. Invention is credited to Crisp, Duane, Lee, Myong J..
Application Number | 20040033297 10/643052 |
Document ID | / |
Family ID | 25366155 |
Filed Date | 2004-02-19 |
United States Patent
Application |
20040033297 |
Kind Code |
A1 |
Lee, Myong J. ; et
al. |
February 19, 2004 |
Food holding cabinet assembly
Abstract
A holding cabinet assembly for holding pre-processed food
products and a process for maintaining the product appearance of a
pre-processed food product for a predetermined amount of time
includes a steamer assembly capable of containing heated water
which is maintained at a first substantially fixed temperature and
a cabinet housing coupled to the steamer assembly and having air
circulated therein with the air in the cabinet housing being
maintained at a second substantially fixed temperature. As a result
of controlling and maintaining the temperature of the water in the
steamer assembly and air in the food cabinet housing, the relative
humidity of the food cabinet housing is maintained at a
substantially fixed value. In this holding cabinet assembly, a
plurality of compartments are arranged in the housing with each
compartment including an openable and closeable drawer. A carrier
insert is adapted to be removably supported in each of the drawers.
Each of the carrier inserts is capable of holding a plurality of
the pre-processed food products whereby the food products in the
carrier inserts can be conditioned at the fixed relative humidity
of the food cabinet housing. In addition, a control indicator is
provided for controlling and sequencing the removal of
pre-processed food products from each compartment before the
expiration of a predetermined amount of time.
Inventors: |
Lee, Myong J.; (Elk River,
MN) ; Crisp, Duane; (Miami, FL) |
Correspondence
Address: |
FROMMER LAWRENCE & HAUG LLP
745 FIFTH AVENUE
NEW YORK
NY
10151
US
|
Assignee: |
Burger King Corporation
Miami
FL
|
Family ID: |
25366155 |
Appl. No.: |
10/643052 |
Filed: |
August 18, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10643052 |
Aug 18, 2003 |
|
|
|
09875661 |
Jun 5, 2001 |
|
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Current U.S.
Class: |
426/418 |
Current CPC
Class: |
A47J 27/14 20130101;
A47J 36/24 20130101; A47J 27/04 20130101 |
Class at
Publication: |
426/418 |
International
Class: |
A23L 001/00 |
Claims
What is claimed is:
1. A food holding cabinet assembly for holding pre-processed food
products comprising: a steamer assembly capable of containing a
water reservoir; first heater means for heating water in the water
reservoir and maintaining the water in the water reservoir at a
first substantially fixed temperature; a cabinet housing coupled to
said steamer assembly and having air circulated therein; second
heater means for heating air passing through the cabinet housing
and maintaining the air in the cabinet housing at a second
substantially fixed temperature so as to maintain a substantially
fixed relative humidity within said cabinet housing; a plurality of
compartments arranged in said housing with each compartment having
an openable and closeable drawer; and a carrier insert adapted to
be removably supported in each of said drawers, each said carrier
insert capable of holding a plurality of said pre-processed food so
that said pre-processed food products in said carrier inserts are
conditioned at the substantially fixed relative humidity of said
food cabinet housing so as to maintain the product appearance of
the pre-processed food products.
2. The food holding cabinet assembly of claim 1 wherein said
pre-processed food products are selected from the group consisting
of cooked baked goods and toasted baked goods.
3. The food holding cabinet assembly of claim 1 wherein said
pre-processed food products are toasted hamburgers buns.
4. The food holding cabinet assembly of claim 1 wherein the first
fixed temperature of the water in said water reservoir is within
the range of between approximately 130.degree. to 180.degree.
F.
5. The food holding cabinet assembly of claim 1 wherein the first
fixed temperature of the water in said water reservoir is
approximately 150.degree. F.
6. The holding cabinet assembly of claim 1 wherein the second fixed
temperature of the air passing through said cabinet is within the
range of between approximately 125.degree. to 150.degree. F.
7. The food holding cabinet assembly of claim 1 wherein the second
fixed temperature of the air passing through said cabinet is
approximately 135.degree. F.
8. The food holding cabinet assembly of claim 1 wherein the
relative humidity in the cabinet is fixed at approximately 70%.
9. The food holding cabinet assembly of claim 1 wherein first and
second heater means are separately controlled.
10. The food holding cabinet assembly of claim 1 and further
including control indicating means for indicating the relative
freshness of the pre-processed food products in each of the
plurality of compartments of the cabinet housing and for sequencing
the selection of the pre-processed food products in each of the
plurality of compartments of the cabinet housing.
11. The food holding cabinet assembly of claim 10 wherein said
control indicating means including a product quality timer being
placed adjacent to each compartment of said cabinet which has
colored light indicators for sequencing the selection of the
pre-processed food products in each of the plurality of
compartments of the cabinet housing.
12. The food holding cabinet assembly of claim 1 wherein each of
said carrier inserts can hold up to ten hamburger buns.
13. The food holding cabinet assembly of claim 1 wherein each of
said carrier inserts includes drainage means for promoting drainage
of moisture form the pre-processed food products held in each of
said carrier inserts.
14. The food holding cabinet assembly of claim 13 wherein said
drainage means includes a plurality of rows of open slits provided
on a supporting surface of each of said carrier inserts.
15. The food holding cabinet assembly of claim 14 wherein adjacent
rows of said plurality of rows of said open slits are substantially
offset from one another.
16. The food holding cabinet assembly of claim 14 wherein alternate
rows of said plurality of rows of said open slits are substantially
aligned with one another.
17. The food holding cabinet assembly of claim 14 wherein each said
open slit in the plurality of rows of open slits is approximately 2
inches long and one-eighth of an inch wide.
18. A process for maintaining the product appearance of a
pre-processed food product for a predetermined amount of time
comprising the steps of: a) heating water in a water reservoir of a
steamer assembly to a first substantially fixed temperature and
maintaining the water in the water reservoir at said first
substantially fixed temperature; b) coupling a food cabinet housing
having a plurality of compartments to the steamer assembly; c)
heating air passing through said food cabinet housing to a second
substantially fixed temperature and maintaining the air in said
food cabinet housing at said second fixed temperature so as to
control and maintain a fixed relative humidity within said food
cabinet housing; d) movably guiding a plurality of drawers each in
a corresponding one of said plurality of compartments; e) placing
pre-processed food products in a plurality of carrier inserts; f)
selectively opening each drawer of the plurality of drawers; g)
removably supporting each of said carrier inserts containing
pre-processed food products in a corresponding opened drawer of
said plurality of drawers; h) closing each of said drawers
removably supporting said carrier insert so that said pre-processed
food products in said carrier inserts are conditioned at the fixed
relative humidity of said food cabinet housing for up to the
predetermined amount of time so as to maintain the product
appearance of the pre-processed food products; and i) controlling
and sequencing the removal of the pre-processed food products from
each compartment before the expiration of the predetermined amount
of time.
19. The process for maintaining the product appearance of a
pre-processed food product for a predetermined amount of time of
claim 18 wherein said pre-processed food products placed in said
carrier inserts are selected from the group consisting of cooked
baked goods and toasted baked goods.
20. The process for maintaining the product appearance of a
pre-processed food product of claim 18 wherein said pre-processed
food products are toasted hamburger buns.
21. The process for maintaining the product appearance of a
pre-processed food product of claim 18 and further comprising the
step of maintaining the first fixed temperature of the water in the
water reservoir of said steamer assembly to be within the range of
between approximately 130.degree. to 180.degree. F.
22. The process for maintaining the product appearance of a
pre-processed food product of claim 18 and further comprising the
step of maintaining the first fixed temperature of the water in the
water reservoir of said steamer assembly at a temperature of
approximately 150.degree. F.
23. The process for maintaining the product appearance of a
pre-processed food product of claim 18 and further comprising the
step of maintaining the second fixed temperature of the air in the
food cabinet housing to be within the range of between
approximately 125.degree. to 150.degree. F.
24. The process for maintaining the product appearance of
pre-processed food product of claim 18 and further comprising the
step of maintaining the second fixed temperature of the air in the
food cabinet housing at a temperature of approximately 135.degree.
F.
25. The process for maintaining the product appearance of a
pre-processed food product of claim 18 and further comprising the
step of conditioning the pre-processed food products in said food
cabinet housing at a fixed relative humidity of approximately
70%.
26. The process for maintaining the product appearance of a
pre-processed food product of claim 18 and further comprising the
step of indicating by colored light differentiation the sequencing
of removal of the pre-processed food products from each compartment
before the expiration of the predetermined amount of time.
27. The process for maintaining the product appearance of a
pre-processed food product of claim 18 and further comprising
filling each carrier insert with up to ten hamburger buns.
28. The process for maintaining the product appearance of a
pre-processed food product of claim 18 and further comprising the
step of promoting drainage of moisture from the pre-processed food
products held in each said carrier insert.
29. The process for maintaining the product appearance of a
pre-processed food product of claim 28 wherein said drainage
promoting step includes the step of providing a plurality of rows
of open slits on a supporting surface of each of said carrier
inserts.
30. The process for maintaining the product appearance of a
pre-processed food product of claim 29 and further comprising the
step of substantially offsetting adjacent rows of said plurality of
rows of open slits from one another.
31. The process for maintaining the product appearance of a
pre-processed food product of claim 29 and further comprising the
step of substantially aligning alternate rows of said plurality of
rows of open slits with one another.
32. The process for maintaining the product appearance of a
pre-processed good product of claim 18 and further comprising
placing a steam baffle plate between said steamer assembly and said
food cabinet housing.
33. The process for maintaining the product appearance of a
pre-processed food product of claim 18 and further comprising the
step of leaning each of said plurality of pre-processed food
products in each of said carrier inserts by providing an angled
surface along a rear surface of each carrier insert which is set at
approximately 41.5.degree. from horizontal.
34. The process for maintaining the product appearance of a
pre-processed food product of claim 18 and further comprising the
step of conditioning said pre-processed food products at the fixed
relative humidity of the food cabinet housing for up to
approximately 90 minutes.
35. A food holding cabinet assembly for holding pre-processed food
products comprising: a food holding cabinet including a plurality
of compartments maintained at a fixed relative humidity with each
compartment including an openable and closeable drawer; and a
plurality of carrier inserts adapted to be removably supported in a
corresponding one of said drawers, each said carrier insert capable
of holding a plurality of said pre-processed food products whereby
the pre-processed food products are subjected to said fixed
relative humidity of said food holding cabinet so as to maintain
the physical characteristics of the pre-processing for a
predetermined amount of time.
36. The holding cabinet assembly of claim 35 wherein each of said
drawers can be independently opened irrespective of the remaining
drawers so that the pre-processed food products in the closed
drawers are not exposed to exterior conditions.
37. The food holding cabinet assembly of claim 35 wherein each of
said carrier inserts includes drainage and air flow means for
promoting drainage of moisture from the pre-processed food products
held in each said carrier insert and for promoting circulation of
air flow around said pre-processed food products.
38. The food holding cabinet assembly of claim 35 wherein each of
said drainage and air flow means includes a plurality of rows of
open slits extending in a direction generally perpendicular to the
direction of opening/closing of the drawer into and out of the food
housing cabinet.
39. The food holding cabinet assembly of claim 38 wherein adjacent
rows of said plurality of rows of open slits are substantially
offset from one another.
40. The food holding cabinet assembly of claim 38 wherein alternate
rows of said plurality of rows of open slits are substantially
aligned with one another.
41. The food holding cabinet assembly of claim 38 wherein each of
said open slit in the plurality of rows of open slits is
approximately 2 inches long and one-eighth inch wide.
42. The food holding cabinet assembly of claim 35 wherein each said
carrier insert includes a back wall angled from horizontal at
approximately 41.5.degree. so that each pre-processed food product
leans against the adjacent food product in said carrier insert so
that the weight of each pre-processed food product is
distributed.
43. The food holding cabinet assembly of claim 33 wherein each
drawer includes air flow openings provided in a bottom wall and
side walls connected to said bottom wall to promote air flow within
said drawer.
44. A food holding cabinet assembly for holding pre-processed food
products comprising: a steamer assembly including a water reservoir
which is maintained at a first substantially fixed temperature; a
cabinet housing mounted on said steamer assembly and having air
circulated therein, said air in said cabinet housing being
maintained at a second substantially fixed temperature so as to
maintain a substantially fixed relative humidity within said
cabinet housing; coupling means for coupling said cabinet housing
to said steamer assembly; and a plurality of compartments arranged
in said housing with each compartment including a separately
openable/closeable drawer with each said drawer capable of storing
a plurality of pre-processed food products therein so that said
pre-processed food products in said drawers are conditioned at the
substantially fixed relative humidity of said cabinet housing so as
to maintain the product appearance of said pre-processed food
products.
45. The food holding cabinet assembly of claim 44 wherein said
coupling means includes a pair of rails provided on top of said
steamer assembly on which a corresponding pair of coupling members
of said food cabinet housing slidable ride so that said food
cabinet housing is slidably movable between a first operative
position, wherein said food cabinet housing is mounted on said
steamer assembly, and a second cleaning position, wherein said food
cabinet housing is moved off said steamer assembly so that an
interior portion of said steamer assembly is exposed for
cleaning.
46. The food holding cabinet assembly of claim 45 wherein a steam
baffle plate separates said steamer assembly and said food holding
cabinet.
47. A process for maintaining the product appearance of a
pre-processed food product for a predetermined amount of time
comprising the steps of a) heating water in a water reservoir of
steamer assembly to a first fixed temperature and maintaining the
water in the steamer assembly at said first substantially fixed
temperature; b) placing a food cabinet housing having a plurality
of compartments in a position so that the steam generated in said
steamer assembly passes into said cabinet housing; c) heating air
passing through said food cabinet housing to a second fixed
temperature and maintaining the air in said food cabinet housing at
a second substantially fixed temperature so as to control and
maintain a fixed relative humidity within said food cabinet
housing; d) movably guiding each of a plurality of drawers in a
respective one of said plurality of compartments so that each
drawer can be independently opened/closed with respect to the other
drawers; e) independently opening each of said drawers and placing
pre-processed food products in said opened drawer; f) closing said
opened drawer into said respective compartment so as to store
pre-processed food products in said respective compartment; g)
conditioning the pre-processed food products at the fixed relative
humidity of said food cabinet housing up to a predetermined amount
of time so as to maintain the product appearance of the
pre-processed food products; and h) independently opening one of
said drawers and removing the conditioned pre-processed food
products from its respective compartment prior to the expiration of
the predetermined amount of time.
48. The process for maintaining the product appearance of a
pre-processed food product for a predetermined amount of time of
claim 47 and further comprising the step of controlling the
sequencing of the removal of the pre-processed food products from
each compartment before the expiration of the predetermined amount
of time.
49. The process for maintaining the product appearance of a
pre-processed food product for a predetermined amount of time of
claim 48 and further comprising the step of holding said
pre-processed food products in a carrier insert which is removably
supported in a corresponding one of said plurality of drawers.
50. The process for maintaining the product appearance of a
pre-processed food product for a predetermined amount of time of
claim 49 and further comprising the step of promoting drainage of
moisture from the pre-processed food products held in each carrier
insert.
51. The process for maintaining the product appearance of a
pre-processed food product for a predetermined amount of time of
claim 48 and further comprising the step of placing a steam baffle
plate between said steamer assembly and said food cabinet housing
to pass steam generated in said steamer assembly into said food
cabinet housing.
Description
BACKGROUND OF THE INVENTION
[0001] A. Field of the Invention
[0002] This invention relates to the field of food holding
cabinets, and more particularly, relates to the field of holding
cabinets for pre-processed food products.
[0003] B. Related Art
[0004] In a bakery, food holding cabinets have been used wherein
fresh baked products are held for a period of time and the air in
the cabinet is maintained at ambient temperature and humidity.
However, these holding cabinets previously employed in bakeries
have been found to be undesirable in a fast food restaurant to hold
toasted baked goods as (a) fast food restaurants require that the
temperature and humidity of the holding cabinet be maintained other
than at ambient temperature and humidity, and (2) the product tends
to dry out in these food cabinets used in bakeries thereby leading
to degradation of the physical characteristics of the product.
Therefore, in fast food restaurants, it has been found desirable to
provide a holding cabinet for pre-processed food products, namely
toasted baked goods, such as toasted hamburger buns, which controls
heat and humidity to maintain product appearance, such as product
softness, taste, and the desired toasted characteristics, also
known in this context as an acceptable caramelized appearance.
[0005] In the fast food industry, it is known to batch toast baked
goods. Batch toasting is advantageous in the fast food environment
as it is less labor intensive and leads to increased productivity.
In one known batch toasting process, the baked food product is
removed from a plastic bag and toasted, then the toasted food
product is reinserted into the plastic bag and then put in a dry
convective heat cabinet.
[0006] This batch toasting process has been found to be
disadvantageous for a number of reasons. First, an intermediate
step is required as the baked food product must be removed from and
then reinserted into the plastic bag, thereby leading to a
consequent increase in labor. In addition, in this prior batch
process, the holding cabinet must be continually opened and closed
because of the convective circuit. This, in turn, leads to further
labor requirements. It has therefore been found desirable to
provide a food holding cabinet assembly for toasted baked goods for
use in fast food restaurants which does not require utilization of
a convection cabinet. It has been further found desirable to
provide a food holding cabinet assembly for toasted baked goods for
use in a fast food restaurant which is easy to use.
[0007] As a further prior example, in order to attempt to maintain
the desired physical characteristics of toasted baked products in
fast food restaurants, the toasted baked products have been placed
in holding steamers or convective ovens. However, these prior
steamers and convective ovens have been unable to control humidity.
Moreover, since these steamers and ovens typically have relatively
large sliding or hinged doors to load the toasted food products
thereinto and remove the toasted food products therefrom, heat and
humidity escape from the unit. In addition, these prior steamers
used in fast food restaurants have limited holding times only, up
to approximately 10 minutes, and limited capacities, as one
example, up to 16 hamburger buns of a 4" diameter and 12 hamburger
buns of a 5" diameter. It has therefore been found desirable to
provide a food holding cabinet assembly for toasted baked good for
use in a fast food restaurant which provides for increased holding
times and product capacities.
OBJECTS OF THE INVENTION
[0008] Therefore, it is an object of the invention to provide a
food holding cabinet assembly for pre-processed food products for
use in a fast food restaurant which avoids the aforementioned
deficiencies of the prior art.
[0009] It is also an object of this invention to provide a food
holding cabinet assembly for pre-processed food products, such as
toasted hamburger buns, which controls heat and humidity to
maintain the product appearance and desired characteristics of the
pre-processed food product.
[0010] It is another object of this invention to provide a food
holding cabinet assembly for pre-processed food products for use in
a fast food restaurant which does not require any intermediate
process step.
[0011] It is further object of this invention to provide a food
holding cabinet assembly for pre-processed food products for use in
a fast food restaurant which does not utilize a convective heater
in the food cabinet.
[0012] It is yet another object of this invention to provide a food
holding cabinet assembly for pre-processed food products for use in
a fast food restaurant which is easy to use and reduces labor
costs.
[0013] It is still another object of this invention to provide a
food holding cabinet assembly for pre-processed food products which
increases the holding time for maintaining the desired product
appearance and increases product capacity within the food holding
cabinet assembly.
[0014] It is yet another object of this invention to provide a food
holding cabinet assembly for pre-processed food products which has
a compartmentalized design for thermal efficiencies.
[0015] It is still a further object of this invention to provide a
food holding cabinet assembly for pre-processed food products for
which only exposes a small portion of the stored food products to
external conditions when the pre-processed food products are
inserted into or are removed from the food cabinet.
[0016] It is also a further object of this invention to provide a
food holding cabinet assembly for pre-processed food products which
has the ability to separate different types of food products for
operational ease.
[0017] It is yet still a further object of this invention to
provide a process for maintaining the desired product appearance of
a pre-processed food product in a food cabinet housing assembly
while increasing the holding time of the food product in the food
cabinet.
[0018] Various other objects, advantages and features of the
present invention will become readily apparent from the ensuing
detailed description and the novel features will be particularly
pointed out in the appended claims.
SUMMARY OF THE INVENTION
[0019] This invention relates to a food holding cabinet assembly
for pre-processed food products which controls heat and humidity
therein to maintain product appearance and desired attributes of
the pre-processed food products. In addition, the present invention
relates to a process for maintaining the product appearance of a
pre-processed food product for a predetermined amount of time in a
food holding cabinet assembly. In accordance with the general
objects set forth above, the food holding cabinet assembly of this
invention does not require any intermediate process step (such as
repackaging of the food products) and does not require use of a
convective heater in the food cabinet.
[0020] The food holding cabinet assembly of this invention includes
a steamer assembly including a water reservoir and a cabinet
housing coupled to the steamer assembly having air circulated
therein. In addition, a air baffle plate separates the steamer
assembly and the food cabinet housing and includes a plurality of
air openings therein which allows air to pass from the steam
assembly into the food cabinet housing. A first heat source heats
water in a water reservoir and maintains the water in the water
reservoir at a first substantially constant temperature. A second
heat source heats air passing through the cabinet housing and
maintains the air passing through the cabinet housing at a second
substantially constant temperature. As a result, the cabinet
housing is maintained at a substantially constant relative
humidity.
[0021] A plurality of compartments are arranged in the cabinet
housing with each compartment having an openable and closable
drawer. In accordance with one of the general objects of the
present invention, the food cabinet herein does not expose any of
remaining pre-processed food products contained therein to the
external environment when pre-processed food products are removed
from a drawer or inserted thereinto. More specifically, each of the
drawers of the food holding cabinet can be independently opened
irrespective of the remaining closed drawers so that the
pre-processed food product in the closed drawers are not influenced
by external conditions.
[0022] In this food holding cabinet assembly, a carrier insert is
adapted to be removably supported in each of the drawers with each
of the carrier inserts being capable of holding a plurality of the
pre-processed food products therein . In one preferred embodiment,
these carrier inserts are capable of holding up to 10 hamburger
buns of a 4" diameter and 7 hamburger buns of 5" diameter.
Therefore, if the food housing cabinet includes 12 such
compartments, the food holding cabinet can accommodate an increased
bun capacity of between 84 to 120 hamburger buns depending upon the
diameter of the buns. When the carrier inserts are removably
supported on the drawers and the drawers are closed so that the
pre-processed food products are contained within the compartments
of the food holding cabinet, the pre-processed food products are
conditioned at the substantially fixed relative humidity of the
food cabinet so as to maintain the product appearance of the
conditioned food products.
[0023] Each of the carrier inserts also promotes the drainage of
moisture from the pre-processed food product supported therein as
well as promotes air flow around the contained food products. In
order to accomplish these advantageous results, each of the carrier
inserts includes a plurality of rows of open slits provided on the
surfaces of each of the carrier inserts supporting the
pre-processed food products. In order to provide better air flow
characteristics, adjacent rows of the plurality of rows of open
slits are substantially offset from one another and alternate rows
of the plurality of rows of open slits are substantially aligned
with one another.
[0024] In order to distribute the weight of the pre-processed food
products supported in the carrier inserts so as to reduce the
chances of undesirable imprints on the food products, the carrier
inserts include an angled rear wall. As a result, each food product
in the carrier insert leans against the adjacent food product in
the carrier insert so that weight is removed from the bottom of the
food product. Consequently, weight is more evenly distributed
throughout the food product. This angled wall also provides for
operational ease because as each food product is removed from the
carrier insert, the angled stack of remaining food products does
not fall.
[0025] Therefore, by employing the compartmentalized design of the
present invention which includes independently openable/closable
drawers as well carrier inserts supporting food products therein,
thermal efficiencies and weight distribution advantages are
achieved.
[0026] In addition, control indicators are provided in the food
holding cabinet assembly of this invention which control the
sequencing of removal of the pre-processed food products from each
compartment before expiration of a predetermined amount of time. In
the preferred embodiment, the pre-processed food products, such as
toasted hamburger buns, can be stored in the food holding cabinet
of this invention and retain an acceptable product appearance for
up to approximately 90 minutes. These control indicators include
colored light indicators which signal the sequencing of removal of
the pre-processed food products from the compartment before
expiration of the acceptable time limit. In particular, each
compartment of the food holding cabinet has associated therewith a
red-light, yellow-light, green-light quality control timer which
indicates the acceptability of product in that compartment.
[0027] As a result of this invention, the temperature and humidity
in the food cabinet housing are easily controlled so as to maintain
product appearance and the products desired attributes, such as the
caramelized appearance of a toasted hamburger bun. Moreover, this
food holding cabinet assemble leads to a reduced labor costs,
increases acceptable holding times and increases product
capacity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The following detailed description given by way of example,
but not intended to limit the invention solely to the specific
embodiments described, may best be understood in conjunction with
the accompanying drawings in which:
[0029] FIG. 1 is an exploded perspective view of a preferred
embodiment of a food holding cabinet assembly in accordance with
the teachings of the present invention.
[0030] FIG. 2 is a front sectional view of the assembled food
holding assembly cabinet of FIG. 1.
[0031] FIG. 2(a) is an enlarged side sectional view of the
compartment of the assembled food holding cabinet assembly
designated in section a of FIG. 2.
[0032] FIG. 3 is a side sectional view of the assembled food
holding cabinet assembly of FIG. 1.
[0033] FIG. 4 is a top view of a carrier insert to be placed in a
drawer which is openable/closeable in a compartment of the
assembled food holding cabinet assembly of FIG. 1.
[0034] FIG. 4(a) is an enlarged top view specifically illustrating
the arrangement of open slits provided in the carrier insert of
FIG. 4.
[0035] FIG. 5 is a side elevational view specifically illustrating
placement of the carrier insert within a drawer of the food holding
cabinet assembly in the side direction of arrow A of FIG. 4.
[0036] FIG. 6 is a front elevational view illustrating placement of
the carrier insert into a drawer of the food holding cabinet
assembly in the rear direction of arrow B of FIG. 1.
DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS
[0037] Referring now to FIGS. 1 through 3 of the drawers, wherein
like reference numerals represent like features in the several
views, a food holding cabinet assembly 10 for holding pre-processed
food products in accordance with the present invention is shown. As
used herein, the phrase "pre-processed food products" shall mean
food products which have been previously processed in some manner,
such as cooked or toasted baked goods, including but not limited to
toasted hamburger buns. This food holding cabinet assembly has been
particularly designed for use in fast food restaurants, but can be
utilized outside the fast food environment as well. As will be
discussed in further detail below, this food holding cabinet
assembly controls heat and humidity to advantageously maintain
product appearance and certain desired attributes of the
pre-processed food-products. For instance, this food holding
cabinet assembly 10 can be utilized to maintain the caramelized
appearance and desired taste of toasted hamburger buns.
[0038] As shown in FIG. 1, the food holding cabinet assembly 10 of
the present invention includes a steamer assembly 12 for generating
steam from water in a water reservoir and a food cabinet housing 20
which is positioned with respect to the steamer assembly 12 such
that the steam generated in the steamer assembly may be admitted
into the food cabinet housing 20. In order to direct steam from the
steam assembly 12 into the cabinet housing 20, a steam baffle
assembly 16 is positioned between the steamer assembly 12 and the
food cabinet 20. The steam baffle plate 16 and the food holding
cabinet 20 can be coupled to the steamer assembly 12. In the food
holding cabinet assembly 10 of this invention, the ability for
decoupling or separating these components promotes cleaning of the
interior of the steamer assembly 12. In this regard, as shown in
FIGS. 2 and 3, a pair of coupling members 21a and 21b extending
downwardly from the side edges 22a and 22b of the food cabinet
housing slidably ride on a corresponding pair of rails 14a and 14b
extending from the top of the side walls 15a and 15b of the steamer
assembly 12. As a result, the food cabinet housing 20 is slidably
movable between a first operative position, wherein the food
cabinet housing 20 is mounted on the steamer assembly 12, and a
second cleaning position, wherein the food cabinet housing 20 is
moved off of the steamer assembly so that the interior portion 17
of the steamer assembly 12 is exposed for cleaning.
[0039] The steamer assembly 12 of this food holding cabinet
assembly 10 may be dropped into an existing countertop or may stand
alone. An example of a steamer assembly which may be used in
conjunction with the food holding cabinet assembly 10 of this
invention is described in U.S. Pat. No. 6,058,926, the disclosure
of which is incorporated by reference herein.
[0040] In the steamer assembly 12 shown in FIGS. 1 and 2 herein, a
water reservoir tray 30 is positioned directly beneath a elongated
opening 32 of an air diversion pan 33 and longitudinally extends
nearly the entire width of the steamer assembly 12 from the front
wall 15b to the rear wall 15d thereof. Steam is generated by
heating the water in the reservoir 30 to above its evaporation
temperature. In one preferred embodiment, a strip heater 34 is
positioned beneath the water reservoir 30 to heat and maintain the
water in the water reservoir at a first substantially constant
temperature above that necessary for evaporation. The operator sets
the desired first constant temperature by means of a water heater
thermostat (not shown). In the preferred embodiment, the first
substantially constant temperature of the water in the water
reservoir is maintained within the range of between approximately
130.degree. to 180.degree. F., and most preferably approximately
150.degree. F.
[0041] In the food holding cabinet assembly 10 of the present
invention, the steam generated in the water reservoir is funneled
through the elongated opening 32 and directs the steam to pass
through the interior space 36 thereof in the manner represented by
arrows b in FIG. 2.
[0042] A second heat source 40 is employed for heating air passing
through the cabinet housing 20 and maintaining the air passing
through the cabinet housing 20 at a second substantially constant
temperature. As but one example, this second heat source can be in
the form of a tubular heating element 40 provided at the top of the
air diversion pan 33 of the steamer assembly 12. However, it is
contemplated that this second air heat source 40 may instead be
positioned within the food cabinet housing 20. Nevertheless, the
air heat source has a setting thermostat (not shown) which is
separate and apart from and does not interact with the setting
thermostat for the water heat source. In the preferred embodiment,
the second substantially constant fixed temperature of the air
passing through the food cabinet is maintained within the range of
the approximately 125.degree. to 150.degree. F., and most
preferably approximately 135.degree. F. Because as noted above, the
constant temperature of the water in the water reservoir 30 is
preferably set within the range of between approximately
130.degree. to 180.degree. F., and most preferably approximately
150.degree. F., the water in the water reservoir is set at a first
substantially constant temperature and the air passing through the
cabinet housing is set at a second substantially constant
temperature, the relative humidity within the food cabinet 12 of
the holding cabinet assembly 10 is thereby maintained at a
substantially constant level. In the preferred embodiment, the
relative humidity within the food cabinet 20 is maintained at
approximately 70%.
[0043] As aforementioned, the air baffle plate 16 is positioned
between the steamer assembly 12 and the cabinet housing 20. As
shown in FIG. 1, the air baffle plate 16 includes a plurality of
longitudinal rows of slit openings, such as 42a and b, and lateral
rows of slit openings, such as 43a and b, through which air passes
from the steamer assembly 12 into the cabinet housing 20. As will
be discussed in more detail below, the rows of slit openings 42a
and 42b substantially correspond to vertical air columns, such as
44a and 44b, provided in the cabinet housing 20 so as to
predominantly direct air within the air columns 44a and 44b.
[0044] As shown in FIGS. 1 and 2, a plurality of compartments, such
as 50a-f, are arranged in the cabinet housing 20 with each
compartment including a corresponding openable and closeable drawer
52a-f slidably guided therein. In FIG. 1, the housing cabinet 20
includes 12 such compartments with only the front compartments
50a-f facing forward. However, the cabinet housing 20 may include
any number of such compartments. As best shown in FIG. 2a, a
compartment drawer, such as 52a, includes guide members 54 and 54b
extending from the sides thereof which ride in a pair of tracks 56a
and 56b extending inwardly from the side edges of the respective
compartment such that the drawer 52a slidably moves with respect to
the compartment 50a between its open and closed conditions.
[0045] Air directed through the air baffle plate 16 passes
predominantly into the central columns, such as 44a and b, of the
cabinet housing 20. These central columns have air openings 45
aligned with each the compartments 50a-50f (see FIG. 3). In order
to promote the circulation of air into the storage compartments 58,
each drawer is provided with a plurality of air inlet openings 59
which are provided along the side surfaces 55a and 55b and bottom
surface 55(c) of each drawer 52a-f. As a result, the air in the
vertical columns 44(a) and 44(b) exits through the column air
openings 45 to pass over the top of the drawers and through the air
inlet openings 59 of each drawer.
[0046] As best shown in FIGS. 4-6, a carrier insert 60 is adapted
to be removably supported in each of the drawers. Each of the
carrier inserts is capable of holding a plurality of the
pre-processed food products, such as 62a and 62b (see FIG. 5). When
the pre-processed food products are removed from their processing
station, such as a toaster, the food products can be placed in a
leaning angled relationship to each other within the carrier insert
60. In the preferred embodiment, the rear supporting surface 65 of
the carrier insert 60 is angled to the horizontal axis at an angle
.theta. of approximately 41.5.degree.. As a result, weight is
removed from the bottom of the food products placed in the carrier
inserts thereby distributing the weight of the food product
therethroughout. Since the weight is so distributed, imprints are
less likely to be formed on the food product due to the size and
configuration thereof. Moreover, this angled rear supporting
surface 65 also provides for operational ease because as each food
product is removed from the carrier insert, the angled stack of
remaining food products in the carrier insert does not fall.
[0047] After the food products are placed in the carrier inserts,
the operator handles the filled carrier insert by means of handles
90a and b and places the carrier insert along the supporting
surface 55c of the drawer such that outwardly extending side
flanges 65a and 65b of the carrier insert are supported on
extending side flanges 67a and 67b of the drawer. Each of the
carrier inserts is capable of holding up to 7 hamburger buns of a
5" diameter and 10 hamburger buns of a 4" diameter. Thus, if the
cabinet housing 20 includes twelve compartments as is shown in
FIGS. 1 and 3, the food holding cabinet assembly 10 can accommodate
120 hamburger of a 4" diameter and 84 buns of a 5" diameter thereby
lending to increased product capacity.
[0048] In order to promote drainage of moisture of the
pre-processed food products supported in each of the carrier
inserts as well as to promote distribution of air flow around the
food products contained therein, the U-shaped supporting surface 70
of each carrier insert 60 includes a plurality of rows, such as
72a-d, of open slits 74. Preferably, each of the open slits 74 are
1/8" (see spacing c in FIG. 4a) by 2" (see spacing d in FIG. 4a).
In order to further distribute air flow, the open slits 74 are
arranged such that adjacent rows of the open slits, such as rows
72c and 72d, are substantially offset from one another, and
alternate rows, such as rows 72a and 72b, are substantially aligned
with each other. In the preferred embodiment, the spacing e between
alternate rows of open slits is approximately 3/4" with the spacing
f between adjacent rows is approximately 3/8" (see FIG. 4a).
Moreover, ends of adjacent open slits in adjacent rows, such as
open slits 74c and 74d, overlap each other by an amount of
approximately 1/4".
[0049] As a result of the design of the cabinet housing 20
described above, each of the drawers 52a-f can be independently
opened irrespective of the remaining closed drawers so that the
pre-processed food products in the closed drawers are not
influenced by external conditions. Therefore, if 12 drawers are
employed in cabinet housing 20, only {fraction (1/12)} of the food
product is exposed to the external conditions at any given
time.
[0050] Because of the compartmentalized design of the food cabinet
housing assembly 10 which maintains substantially constant
temperature and humidity within the food cabinet 20, the
pre-processed food products are able to be held within the cabinet
for up to approximately 90 minutes without the addition of any
intermediate step, such as the repackaging step employed the prior
art. Therefore, the present invention provides for labor reduction
as a fast food restaurant worker does not, for instance, need to
feed many hamburger buns into a toaster during peak hours.
[0051] The holding cabinet 20 of the food holding cabinet assembly
10 of this invention also includes a control indicating mechanism
for controlling and sequencing the removal of the pre-processed
food products from each compartment before the expiration of a
predetermined time, that is, before the 90 minutes limit for food
products in the cabinet housing expires. To achieve this object,
each of the compartments includes a corresponding colored light
indicator 80a-f controlled by a timer. Each light indicator signals
by color differentiation the sequence of removal of the
pre-processed food products from each of the compartments. These
light indicators 80a-f employ a red-light, yellow-light,
green-light coloring scheme to signal which compartment should have
its food product removed first. If the light indicator is green,
the food product in that food compartment should be used first. If
the light indicator is yellow, newer product is contained in that
compartment and food product in a compartment designated with a
green light should be removed first. A flashing red light means the
food product in that compartment has expired and a steady red light
on the light indicators represents that no product is present in
that compartment.
[0052] The food cabinet 20 of the food holding cabinet assembly 10
of this invention is also self-sanitizing. After all of the
pre-processed food products have been removed from the compartments
of the food cabinet, the cabinet is automatically run at a
temperature up to preferably 200.degree. F. for a predetermined
period of time and then shuts off. In this manner, all of the
compartments of the food cabinet can be sanitized at regular
intervals. This self-sanitizing feature thus ensures food safety
and reduces labor requirements.
[0053] This invention is also directed to a process for maintaining
the product appearance of a pre-processed food products for
predetermined time. In that process, water is heated in the water
reservoir 30 by the water heater 34 and maintained at a constant
temperature preferably within the range of 130.degree. to
180.degree. F., and most preferably 150.degree.0 F. The food
cabinet 20 is coupled to the steamer assembly so that the steam
generated in the steamer assembly passes into the food cabinet
housing. The second heat source 40 heats the air passing through
the food cabinet to a second constant temperature and the air in
the food cabinet housing 20 is maintained at that second constant
temperature which is preferably within the range of 125.degree. to
150.degree. F., and more preferably, approximately 135.degree. F.
As a result thereof, the process of the present invention maintains
the relative humidity within the cabinet housing at a constant
value, preferably 70%.
[0054] Each of the plurality of drawers 52a-f of the cabinet
housing 20 is movably guided in one of the compartments 50a-f of
the cabinet housing 20 so that each of the drawers can be
independently opened/closed with respect to the other drawers. The
pre-processed food products are removed from the processing
station, such as a toaster, and placed in one of the plurality of
carrier inserts 60. The carrier inserts are adapted to be removably
supported within one of the drawers. When the drawers are closed
into the respective compartments 50a-f of the cabinet housing 20,
the pre-processed food products are conditioned at the constant
relative humidity of the food cabinet for a predetermined about of
time (such as the acceptable time limit for hamburger buns is 90
minutes) so as to maintain the product appearance and desired
attributes of the pre-processed food products. One of the drawers
can be independently opened so that the conditioned pre-processed
food products can be removed therefrom prior to the expiration
time. In addition, by means of the control indicator timers
discussed above, the removal of the pre-processed food products
from each of the compartments before the expiration time can be
controlled and sequenced.
[0055] Therefore, in accordance with one of the general objects of
the present invention, a food holding cabinet assembly for
pre-processed food products has been provided which controls heat
and humidity within the food product cabinet to maintain product
appearance and desired attributes of the food products, such as the
caramelized characteristics of a toasted hamburger bun. Further,
the present invention also provides a food product holding cabinet
assembly which is easy to use, of reduced costs, and results in
increased holding times and product capacities. Moreover, the
design of the individualized compartments, drawers and carrier
inserts provides for thermal efficiencies and only exposes a small
portion of the pre-processed food products to external conditions
when a portion of the food products are removed from or inserted
into the holding cabinet. In addition, the compartmentalized design
has the ability to separate different types of food products, such
as toasted 4" and 5" hamburger buns, for operational ease.
[0056] Although the invention has been particularly shown and
described with reference to certain preferred embodiments, it will
be readily appreciated by those of ordinary skill in the art that
various changes and modifications may be made therein, without
departing from the spirit and scope of the invention. It is
intended that the claims be interpreted as including the foregoing
as well as various other such changes and modifications.
* * * * *