Note: Descriptions are shown in the official language in which they were submitted.
CA 02487974 2004-11-17
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Attorney Locket No. P350.120.102
APPARATUS AND METHOD FOR PREPARING MULTIPLE PIZZAS
CROSS-REFERENCE TO RELATED APPLICATIONS
The subject matter of this patent application is related to the subject matter
of U.S.
Provisional Patent Application No. 60/446,479, filed February 10, 2003,
priority to which
is claimed under 35 U.S.C. ~ 119(e) and which is incorporated herein by
reference, and
the subject matter of this patent application is also related to the subject
matter of U.S.
Design Patent Application No. (Attorney Docket No. P350.122.101), filed
February 10, 2004, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Pizza is one of the most popular food items in the United States. Pizzas come
in
many different shapes and sizes, with virtually unlimited variation in the
types of
toppings, meats, vegetables, cheese, doughs/crusts and other ingredients used.
Pizza
makers select and assemble these ingredients to create a taste, aroma, texture
and
consistency in accordance with the desires of their selected audience.
Commercial pizza
makers with national and international presence, especially pizza restaurants,
typically
select, develop and promote a number of different pizzas, varying at least in
the number
and type of toppings.
So that one or more consumers can enjoy different styles or types of pizzas in
one
sitting, it is often desired to provide pizzas made-to-order in one way on one
portion of
the pizza, and in another way on another portion of the pizza. A customer or
group
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customers in a pizza restaurant, for example, might order one topping on one-
half of the
pizza and another topping on another half of the pizza. Potential difficulties
arise,
however, in that different topping types may not be distributed or maintained
exactly as
desired. For example, one topping type intended for one portion of the pizza
may spill
over to the other portion of the pizza when the pizza is made, or toppings may
slide off
their intended portion of the pizza when the pizza is cut. Additionally, pizza
may not be
cut exactly at the division line between the differently prepared portions. It
can also be
operationally difficult to combine certain pizza variations into a single
pizza.
SUN)NIARY OF THE INVENTION
An apparatus for holding multiple pizzas includes a pan and an insert adapted
to
fit within the pan. The insert includes a plurality of sidewalls extending
between a base
of the insert and an upper portion of the insert, and the sidewalls generally
surround a
plurality of openings defined by the insert in the base. The insert is adapted
to fit within
the pan such that each of the multiple pizzas contacts a bottom of the pan and
the
sidewalk of the insert. A method of making multiple pizzas includes placing a
support
into a cooking vessel, placing dough across the support to form multiple dough
portions,
placing ingredients on the multiple dough portions to form multiple pizzas,
and placing
the support and the cooking vessel into a heating environment to bake the
multiple
pizzas.
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BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will be described with respect to the figures, in
which like reference numerals denote like elements and in which:
Figure 1 is a perspective view of an apparatus for holding multiple pizzas,
according to an embodiment of the invention.
Figure 2 is a side view of a pan insert, according to an embodiment of the
invention.
Figure 3 is a top view of a pan insert, according to an embodiment of the
invention.
Figure 4 is an end view of a pan insert, according to an embodiment of the
invention.
Figure 5 is a perspective view showing dough being placed into the Figure 1
apparatus, according to an embodiment of the invention.
Figure 6 is a perspective view showing division of the Figure 5 dough,
according
to an embodiment of the invention.
Figure 7 is a perspective view showing a saucing process, according to an
embodiment of the invention.
Figure 8 is a perspective view showing an ingredient layer, according to an
embodiment of the invention.
Figure 9 is a perspective view showing multiple pizzas, according to an
embodiment of the invention.
Figure 10 is a perspective view showing multiple pizzas being conveyed into an
oven, according to an embodiment of the invention.
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Figure 11 is a perspective view of multiple pizzas, according to an embodiment
of
the invention.
Figure 12 is a perspective view showing cutting of the Figure 11 pizzas,
according
to an embodiment of the invention.
Figure 13 is a perspective view of a composite pizza formed of the Figure 11
pizzas, according to an embodiment of the invention.
Figure 14 is a perspective view of an apparatus for holding multiple pizzas,
according to an embodiment of the invention.
DETAILED DESCRIPTION
Figures 1-4 illustrate apparatus 10 for holding multiple pizzas or other food
products. Apparatus 10 comprises pan 15 having bottom 20. Pan 15 is a standard
generally rectangular baking pan, according to the illustrated embodiment,
i.e. a pan that
many pizza restaurants typically have on-hand as a stock item for bread sticks
or other
food items. Bottom 20 is generally rectangular and generally flat, as
illustrated. Pan 15
also includes upstanding sidewalls 25, 30, 35, 40 defining four corners
between them. It
should be understood that shapes other than generally rectangular are
contemplated, for
example generally circular, generally square, generally triangular, generally
polygonal,
generally trapezoidal, etc. Pan 15 is constructed of aluminum, steel, or other
heat-
conducting metal or material, according to embodiments of the invention.
Apparatus 10 further comprises frame, or insert, 50. Insert SO is adapted to
fit
within pan 15, as indicated by lines 52. Insert 50 is divided into two
portions, or
divisions, 54, 56. Portion 54 includes a plurality of sidewalls 60, 62, 64,
66, and portion
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56 includes a plurality of sidewalls 68, 70, 72, 74. The sidewalls of insert
50 extend
between a base plane or base 80 of insert 50 and an upper portion or plane 85
of insert 50.
The sidewalls generally border or surround a plurality of openings 90, 95
defined in base
80 by insert 50. Insert 50 is adapted to fit within pan 15 such that each of
the multiple
pizzas or other food products contacts bottom 20 of pan 15 and the sidewalls
of insert 50.
Further, sidewalls of insert 50 are angled with respect to base 80 and upper
portion 85
such that dough located within portions 54, 56, for example a single dough
sheet that has
settled into portions 54, 56, as will be described, is upturned and angled in
a manner to
provide a "separate-pizza" appearance, i.e. to create an appearance of
multiple, separately
prepared pizzas in the finished, baked product, each pizza having four crust
edges.
According to one particular embodiment, the obtuse angle formed between each
of the
sidewalls of insert 50 and base 80 is about 122 degrees, although other angles
are also
contemplated.
Insert 50 defines a generally rectangular shape, as illustrated. Openings 90,
95 are
two in number, are of a generally square shape, and are for forming two
generally square
pizzas, in the illustrated embodiment. Other embodiments of the invention
contemplate
other shapes for insert 50, e.g. shapes corresponding to the shape of pan 15.
As with pan
15, generally circular, generally square, generally triangular, generally
polygonal,
generally trapezoidal, etc. shapes are contemplated for insert 50. Further, as
with pan 15,
insert 50 is constructed of aluminum, steel, or other heat-conducting metal or
material,
according to embodiments of the invention. Insert 50 optionally is stamped
from a single
piece of metal so as to be one piece. Alternatively, insert 50 is extruded,
molded, or
otherwise formed to be a single piece. Additionally, insert 50 optionally
includes any
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desired number of openings in base 80, for example four openings, six
openings, eight
openings, or any other desired number. The number of openings generally
corresponds
to the number of pizzas or other food products contemplated for production,
but other
ratios of food product to opening also are contemplated.
Insert 50 defines center bar 100 disposed above upper portion 85 of insert 50.
As
will be described with reference to Figures 5 and following, center bar 100
and the
sidewalk of insert 50 are arranged such that a single sheet of dough laid
across insert 50
is readily divided along center bar 100 to form separate crusts for the
multiple pizzas.
Center bar 100 is illustrated with a rounded upper surface designed to promote
division,
i.e. cutting or separation, of dough laid across it. Angled or other upper
surfaces for
center bar 100 also are contemplated.
Insert 50 also defines a generally planar platform 105 extending in upper
portion
85 outwardly from the sidewalls of insert 50. Platform 105 is disposed on
opposite sides
and opposite ends of center bar 100; insert 50 as illustrated in Figure 1 thus
also can be
considered to include two or four separate platforms, one (or two) each on
either side of
center bar 100, and one (or two) each on either end of center bar 100. As will
be
described, platform 105 provides back pressure against a roller or other
device used to
divide or contact dough laid across center bar 100. Extending along edge 115
of platform
105 is lip 110, which extends toward base 80 and is intended to structurally
strengthen
insert 50, i.e. to generally prevent or inhibit bending of insert 50 along
center bar 100
absent excessive force. Insert 50 includes two lips 110, one adjacent each end
of center
bar 100.
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Insert 50 also defines a plurality of dough guides 120 adapted to generally
center
or otherwise position dough laid across insert 50. Dough guides 120 extend
above upper
portion 85. Dough guides 120 define generally angled or ramped surfaces that
serve to
maintain dough placed across insert 50 in a desired position in the widthwise
(front-to-
rear) direction as viewed in Figure 1. In the lengthwise (left-to-right)
direction as viewed
in Figure 1, sidewalls 25, 35 of pan 15 generally serve to center or maintain
the dough in
a desired position. Dough guides 120 are especially desirable in the situation
where
dough is placed onto insert 50 in a generally frozen state, and then moved to
a cooler or
other second location for tempering, or thawing. Once the dough begins to
temper, or has
tempered, it settles into insert 50 and is more difficult to reposition. Dough
guides 120
help ensure proper positioning of the dough before the tempering process
begins. Dough
guides 120 are positioned with respect to the remainder of insert 50 in a
manner to
accommodate the largest size of dough expected to be used, e.g. the largest
spec tolerance
envisioned being received from a dough vendor. In certain cases, end-to-end
dough
tolerances in vendor-sourced dough are tighter than side-to-side tolerances,
so the degree
of tolerance accommodated by the ramped portion of dough guides 120 is
correspondingly greater than the degree of tolerance accommodated by sidewalls
25, 35
at the ends of pan 15.
Stabilizers 125 extend from dough guides 120 toward base 80. Stabilizers 125
are
spaced from the sidewalls of insert 50 and are adapted to contact bottom 20,
and/or
sidewalls 25, 30, 35, 40, of pan 15. Stabilizers 125 generally prevent rocking
or
wobbling of insert 50 within pan 15, for example when a roller or other tool
is placed in
contact with dough on top of insert 50, or when other external force or motion
is imparted
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to insert SO and/or pan 1S. Outer ends of stabilizers 125 are angled, as
illustrated, to
reduce or generally eliminate interference with pan 15.
Thus, according to embodiments of the invention, apparatus 10 can be
considered
to include frame SO for supporting multiple food products, such as pizzas.
Frame 50
defines a rim, e.g. including the previously described sidewalls, the rim
generally
surrounding a plurality of separated bottom openings 90, 9S, one opening for
each of the
multiple food products. Openings 90, 9S are for transmission of thermal energy
to the
multiple food products supported by the rim. Frame SO is adapted for placement
within
pan 1S to directly support the multiple food products through the bottom
openings 90, 95.
Center bar 100, and/or sidewalls 64, 68, define a cross-member or raised
portion
extending across frame 50 between bottom openings 90, 9S and is adapted to aid
in
cutting dough laid on frame S0.
As will be appreciated from e.g. the side view of Figure 2, inserts SO
according to
embodiments of the invention are shaped such that multiple inserts nest one
within the
other to form a stack of inserts. Multiple inserts thus are stored in a
relatively compact,
relatively secure stack, if desired.
Those of ordinary skill will also appreciate that a wide variety of dimensions
are
contemplated according to embodiments of the invention. According to one
example, a
length of insert SO is about 12 inches, more specifically about 12.19 inches,
and a width
of insert SO is about 8 inches, more specifically about 8.30 inches. Each
insert SO is
optionally of a height less than the height of sidewalls 25, 30, 35, 40 of pan
1S, so that
pans 1 S with inserts SO still within them may be stacked in a partially
nested
configuration. According to one embodiment, such stacking occurs after the
food
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products are baked and removed, for example while pans 15 cool and/or await
washing.
In that regard, the underside of bottom 20 of an upper pan in the nested stack
optionally
rests on dough guides 120 of insert 50 placed in a next lower pan 15.
Method aspects according to embodiments of the invention now will be described
with respect to Figures 5-13. A method of making multiple pizzas includes
placing insert
or support 50 into cooking vessel 15, for example into the standard generally
rectangular
baking pan referenced above. The method further includes placing dough 150
across
support 50, indicated by arrows 155 in Figure 5. Figure 5 illustrates two
dough sheets, or
disks, 150 placed across two supports 50 placed in two pans 15, for production
of four
separate pizzas. According to other embodiments, other numbers of inserts 50
and pans
15, for example one, three, or four, are used to produce other numbers of
pizzas, for
example two, six or eight. Further, although illustrated dough sheets 150 are
generally
rectangular in shape to match the generally rectangular shape of inserts 50,
other shapes
of dough sheets are also contemplated, for example generally circular,
generally square,
generally triangular, generally polygonal, and generally trapezoidal shapes.
Food release
or other non-stick agent optionally is applied to pan 15 and/or insert 50
before placement
of dough 150.
Upon placement onto supports 50, dough sheets 150 are generally frozen, and/or
at least partially frozen, according to embodiments of the invention. Sheets
150 thus are
generally stiff and retain their shape upon placement onto supports 50. To the
extent that
original placement of the sheets 150 or subsequent external forces de-center
or otherwise
dislodge dough sheets 1 SO with respect to support 50, dough guides I20 of
support 50
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and/or sidewalls 25, 35 of pan 15 serve to center sheets 150 and/or otherwise
move them
to a desired position.
According to embodiments of the invention, dough sheets 150 are allowed to
temper, or thaw, while disposed on support 50 within pan 15. A method
according to an
embodiment of the invention thus includes thawing a generally frozen sheet of
dough 1.50
on support S0. The length of thawing time is set according to characteristics
of the dough
and/or other physical or environmental properties associated with apparatus
10. One
embodiment provides for at least about eight hours of thawing time at about 38
degrees
Fahrenheit. Multiple pans 15 with supports 50 optionally are stacked on top of
each other,
for example with lids over each pan 15 to support the bottom of a next higher
pan in the
stack, in a cooler or other thawing environment.
As dough sheets 150 thaw, they settle into divisions 54, 56 and assume a shape
generally corresponding to the sidewalls of support 50 and bottom 20 of pan
15, e.g. in a
generally "draped" configuration. The method thus includes placing dough 150
across
support 50 to form multiple dough portions 160, 165. Once the thawing process
is
complete, for example, the method further includes dividing dough sheets 150,
such that
multiple dough portions 160, 165 become separated. Figure 6 illustrates dough
roller
170, which is an example of a device used to perform the dividing. Rolling
roller 170 on
each dough sheet 150 along center bar 100 separates each dough sheet 150 into
the
separate portions 160, I 65. Platforms) I05 provide additional support and
back pressure
against roller 170 to aid the dividing process, as referenced earlier in this
patent
application. The flat area of platforms) I05 provides room for roller 170 to
travel
beyond the edge of dough 150 and completely cut dough 150 to its edge.
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After the dividing, the edges of portions 160, 165 extend generally to the top
of
each sidewall of support S0, though some sagging or other downward movement of
the
edges is acceptable. Positioning edges of portions 160,165 at the top or
almost at the top
of the sidewalk is desirable, though not necessarily required, to better
promote an
appearance of multiple, separate pizzas, each with their own crust.
A method according to embodiments of the invention next includes placing
ingredients on multiple dough portions 160, 165, to form multiple pizzas. Such
ingredients optionally include pizza sauce I7S, shown in e.g. Figure 7. Sauce
I7S
optionally is applied by spreader 180. Spreader 180 has bowl portion 185
generally
corresponding to the shape of each portion S4, S6 of support SO and/or to the
shape of
multiple separate dough portions 160, 165. According to the illustrated
example, bowl
portion 18S is generally square-shaped, corresponding to generally square-
shaped support
portions S4, S6 and/or dough portions 160, 165. Each comer of bowl portion 18S
is
pushed or moved to a corresponding corner of each dough portion 160, 165, to
spread
sauce across generally the entire bottom of dough portions 160, 165, including
into the
corners thereof, without having to turn or lift spreader 180.
The ingredients placed on multiple dough portions 160, 16S also optionally
include bottom cheese 190, illustrated in e.g. Figure 8, and meats 192,
vegetables/fruits
194, 196, top cheese, or any other food items or toppings suitable for
placement on pizza
products, as illustrated in e.g. Figures 9-10. Meats 192 optionally include
pepperoni,
sausage, ham, and/or bacon, to name several examples, and vegetables/fruits
194, 196
optionally include green peppers, mushrooms, black olives, and/or tomatoes, to
name
several examples. The placing of ingredients according to a method embodiment
of the
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invention includes placing different types and/or combinations of ingredients
on multiple
dough portions 160, 165 such that multiple pizzas 200, 202, 204, 206 are of
different
kinds.
As illustrated in Figure 10, a method according to an embodiment of the
invention
further includes placing support 50 and pan or other cooking vessel 15 into a
heating
environment, for example conveyor oven 210 via conveyor 215, to bake multiple
pizzas
200, 202, 204, 206. The placing into a heating environment includes placing
two pans or
other cooking vessels 15 end-to-end, as in Figure 10, for generally
simultaneous entry
into and traversal through the heating environment. Conveyor 215 conveys pans
15 into
heating environment 210 in generally a width-wise or transverse direction, as
illustrated.
Placing pans 15 end-to-end provides a number of advantages, including more
easily
keeping the multiple pizzas of a single customer order together, and more
easily ensuring
that the multiple pizzas all are baked uniformly and for the proper amount of
time. If
pans 15 are placed in a direction perpendicular to that shown in Figure 10,
for example,
they are more likely to be removed from a conveyor oven when only a first end
has
emerged from the oven, meaning that the food product at the second, trailing
end might
be undercooked. According to embodiments of the invention, the baking process
within
oven 210 occurs at a temperature in a range of about 400 degrees to about 500
degrees
Fahrenheit, and more particularly about 450 degrees Fahrenheit, for a length
of time in a
range of about 7 minutes to about 9 minutes, and more particularly about 7.5
minutes or
about 8.5 minutes.
As illustrated in Figure I l, a method according to an embodiment of the
invention
also includes removing multiple pizzas 200, 202, 204, 206 from supports 50
after pans 15
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emerge from oven 210 or otherwise after the baking process is complete. Each
of the
multiple pizzas is removed from their respective portions 52, S4 of supports
50, for
example using spatula or other utensil 280, and placed on peel or other
support 282, for
example a pizza box or pizza box insert.
In the illustrated example, each of the four multiple pizzas is placed next to
an
adjacent pizza to form composite pizza 285, as shown in e.g. F Døure 12. The
method
further includes cutting across multiple pizzas of composite pizza 285 in one
or more
single cutting strokes using rocker knife 298, for example, to divide the
multiple pizzas
into slices 300. In the illustrated example, the method includes cutting
across four
multiple pizzas 200, 202, 204, 206 in four cutting strokes 290, 292, 294, 296,
to create
sixteen individual slices 300 of pizza.
Thus, according to embodiments of the invention, a method of baking a
plurality
of pizzas 200, 202 and/or 204, 206 in a single pan 15 includes placing insert
50 into pan
15, placing dough 150 onto insert 50, dividing dough 150 into portions 160,
165, topping
dough portions 160, 165, and baking topped dough portions 160, I65 to form a
plurality
of baked pizzas 200, 202 and/or 204, 206. The placing includes placing a
single
generally frozen dough sheet 150 onto insert 50. Figure 13 illustrates
composite pizza
285 comprising multiple individual pizzas 200, 202, 204, 206 and slices 300.
Figure 14 illustrates an alternative embodiment. Frame 310 supports multiple
food products, such as multiple pizzas. Frame 310 defines rim 315 for
supporting the
multiple food products. Rim 315 defines a plurality of separated bottom
openings 320,
325, 330, 335, one opening for each of the food products, for transmission of
thermal
energy to the food products supported by rim 315. Frame 310, including rim
315, is
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adapted to support a plurality of separate food-product pans 34.0, one pan for
each of the
multiple food products, over each of bottom openings 320, 325, 330, 335 in
frame 310.
Frame 310 further defines cross-member 345 extending across frame 310 between
two of
the openings 320, 335 and between two of the openings 325, 330. Frame 310 also
defines cross-member 350 extending between two of the openings 330, 335 and
between
two of the openings 320, 325.
Frame 310, also called a carrier, holder or caddie, is designed to support and
accommodate four individual pizza pans 340, as illustrated. Each pan 340 fits
within and
is supported on a corresponding separate quadrant of frame 310. Each pan 340
defines
four protruding tabs 355, which are used to aid in moving or otherwise
manipulating pans
340 to or form the various quadrants of frame 310 or other locations. Each pan
340 also
includes perforated bottom 360, which allows connective heat to pass directly
therethrough, and upstanding sidewalls 365, which extend at an angle relative
to
perforated bottom 360. Lip 370 extends between each sidewall 365 and its
corresponding
tab 355. Tabs 355 intersect their respective lips 370 at an angle intended to
nunimize
undesired tilting of pan 340 upon gripping by a gripper or other tool.
Frame 310 includes bottom portion 375, with four sidewalls 380 extending
upwardly at an angle from bottom portion 375. That angle is optionally the
same, or
about the same, as that between each sidewall 365 and perforated bottom 360 of
pans
340. Each sidewall 380 of frame 310 includes outwardly directed lip 385, from
which
tab 390 extends for manipulation by a pan gripper or other tool. Four tabs 390
are
provided, according to one embodiment, one on each of the four sides of frame
310.
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Tabs 390 thus permit easy manipulation by a tool for insertion into or removal
from an
oven or other location.
Upstanding from bottom portion 375 are a plurality of frame tabs 395, for
example eight frame tabs as illustrated in Figure 14, which are constructed to
act as
supports for pans 340. Tabs 395 are disposed with respect to bottom portion
375 at an
angle of between about 60 degrees and about 90 degrees, for example, and/or
optionally
to match or accommodate the angle between each sidewall 365 and bottom 360 of
each
pan 340. Four. openings 320, 325, 330, 335 are provided, one for each of the
four pans
340 supported on frame 310, according to the illustrated embodiment.
Alternative
embodiments contemplate additional numbers of openings and a corresponding
additional numbers of pans, for example two openings and pans, six openings
and pans,
etc.
Pans 340 fit within frame 310. Tabs 395 of frame 310 engage corresponding
sidewalls 365 and/or lips 370 of pans 340, and optionally contact the lines of
intersection
between sidewalk 365 and their corresponding lips 370 or areas immediately
adjacent the
lines. Each pair of tabs 395 for a particular quadrant of frame 310 serves to
level its
corresponding pan 340, to position it at the proper position on frame 310
and/or to
position it properly with respect to the other pans 340 that frame 310
supports.
When one or more pans 340 are supported by frame 310, the underside of
perforated bottom 360 of each pan 340 is exposed directly, through a
corresponding
opening 320, 325, 330, 335 in frame 310, to baking heat generated by the oven
or other
heating environment into which frame 310 is placed. An outer edge of each
underside is
supported directly on bottom portion 375 of frame 310 to cover and surround
respective
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openings 320, 325, 330, 335. Other features according to the Figure 14
embodiment,
including method features, are described in U.S. Provisional Patent
Application No.
60/446,479, incorporated by reference above.
Embodiments of the invention allow a group of pizza eaters to mix and match
their favorite toppings so that each person gets his or her own individual
pizza. Four
different individual pizzas, topped four different ways, for example, fill a
serving utensil
or a pizza box comer-to-corner, in a manner similar to that of a single pizza.
Embodiments of the invention are specifically directed toward pizza-type food
products. Embodiments of the invention have wide application for use in
cooking and
preparing other foods and food products, however, including pies, cookies,
pastries, etc.
Thus while certain embodiments have been described with respect to pizza, the
invention
is not limited to those embodiments. Additionally, those of ordinary skill
will appreciate
that the invention contemplates a large number of variations and modifications
beyond
those specifically disclosed herein, including but not limited to additional
dimensions,
materials, shapes, and other features not specifically described herein.
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