Note: Descriptions are shown in the official language in which they were submitted.
2 ~ L~
~inition~ and ~ .ig~
Because o~ new structurally~ae~thQtic di~r~nces, the
container which thi~ inYention i~ design~d to shap~ and bake
cannot propQrly bQ identiPied w~th any oX th~ ~peci~lc na~e~
and~or structures used for prior~art edibl~ containers even
though it is consumed in ~h~ sam~ mann~r, i.e.; eaten while held
by a person's hand. Foods eaten in thi~ ~anner are known in the
~ood indu~try a~ "finger-~oods." "Fing~r-fosd~" are tho~ that
can b~ held by a per~on'0 fingers dir~ctly or by holding an
edible containsrfpaakage conveyed to t~ mouth w~thout the
a~sistance o~ any acces~ory materials, and, ideally, without
soiling said ~ing~rs.
An edib}e contain~r b~co~e~ an edibl~ ~inger-food
package wh~n ~00d8 ar~ ~illsd, pack0d, and contain~d therein or
ther~on, and th~r~by can b~ hand-convey~d to ~ mouth and eaten.
So~e prior-art typ~ 0~ such ~ing~r-~ood adible-container-
p~ckag~ hava ~cquir~d ~p~ci~lc n~mo~ ~or th~ir u~ with
sp~cl~ic cont~nt~ such a~: hot-dog bun~, h~mbu~ger bun~,
tar~-cup~, pita~pook~t breada, burrito and t~co sholl~, and
ic~-cr0s~ conQ3~ Th~ae nam~ h~vo acguir~d unigue ~aning~ with
con~u~r~ that id~n~ify, and ara g0n~rally d~crlptiv~ o~,
3paci~ic ~unction~ ~n~ ~hapes ~or ~poci~ic ~ood u~
Th~ N~ n
By contra~t th~ fing~r-food Qdible cont~in~r which ~his
iQvention is de~ign~d to ~hape and bak~ o n~w and its
m~rketplac~ exposur~ ~o limited i~ h~s not y~t acquir~d a unique
~eaning with consumer~. ~ut becaus~ said contain~r ha3 a deep
c~ntrally reces~@d de~i~n s~ruc~ure, on~ ~ha~ can encircle its
contents, it ha~ ths abili~y to pxesent it~ content~ to the
cons~mer in a n~atly attrac~ive manner ~at is vi~ibly different
from any bun or other ~dible container-packag~. ~o help ~h~
2 ~ 6 l~
con~u~r recogniz~ thi~ visibly dl~er~nt d0~gn~d ~hap~ wl~hin
the broad ~lnger-~ood clas~ ati~ns I hav~ named it Boat Bun
und~r the Rsgistered Trademark No. 1,449,946 and described its
appearance under De3ign Trad~maxk No. 1,539,865.
The de~ign o~ the ~oat~ ~un p~r~lts it to hold many
dif~erenk kind~ and size~ o~ ~ood cont~nts. Thi~ d~sign is not
limitQd by any l~ngth, width, or d~pth dim~n3ion~; nor by the
phy~ical charact~ristic~ o~ it~ bak~d dough; such ~a t~xture,
hardnes~, softness, weakn~ss, ~trength, or fl~xibility. Its
neatly attrac~ive, de~ign/shap~ i~ its only unigu~ li~itation;
which limitation i~ obviou~ly/adequately racognizable in the
Dssign Trade~ar~ 1,539,865.
Wi~h thdt limitation th~ r~ces~d shap~ ~ay ba
structured to accommodate peculiar r~qu~rem~nt~ ~or p~culiar
contents. For thi~ inv~ntion the ~xemplary paculiar contents
are a frank~urter/hot-dog and it8 dr~ing~. In the prior-art,
univer~al consu~ption of ~rank~urters i~ in th~ wsll known
elongat~d ~plit bun known a~ ths ~hot-dog bun~ n Thi~ bun i5
baked u~ing ~ ~tandard whito-bre~d t ~ ~ dough which
characteri~tically h~ a ~o~t, ~pongy t~xture, and l~ inch
thick, r~latively in~l~xiblo, w~ak wall~ with no cavity.
B~caus~ consu~r~ d~ire th~ ~o~tn~0s and ~pongin~ o~ th~
prior-~rt bun~ tha n~w art o~ thi~ inv~ntion will ~ub~tantially
r~tain th~ de~ir~ble charact~ri~tic~0 ~C~U~Q COn~U~er5
di~lik~ the weakn~ss and poor flexibility o~ tho prior-art's
hot-dog bun, thi~ in~ention wi}l provide graatly in~r~a~ed
str~ngth and ~lexibility in its walls.
~ cco~modating consumer pre~er~nce~ i~ a de~irable
o~iective in mark~ting any new productc I~ i3 an objec~iYe of
thi3 invention to accommodate and improv~ on ~uch pre~erences
and illustra~e this ob~ective through-ou~ thi~ closure by
-2-
A ) ~
comparing th~ Boat~ Bun with it~ well-known; univ2r~ally-used,
priox-art countsrpart, namely th~ elongated xplit bun.
Therafor~, ~or bs~t mark~tablllty i u~d ~ub~tantially the
bread-typ~ dough o~ tha prior-art hot-dog bu~ in my pres~nt
costly, manually produced, but nevQrtheless successful,
small-scale marketing o~ the BoatD ~un. But to ~hape, bak~, and
successPully market the ~oat~ Bun for large-scalQ, hlgh volume,
commerclal sal~s it i~ necQs ary that it be produced by a
low-cost au~omatad production line. In att~mpting to build such
a production line I was confronted with several unforeseen
intractable probl~m~, which arQ the concern o~ thi~ invention.
During nine year~ of production fro~ 19~2 to 1991, I
shaped and baked my Boat~ 8un edible container with it-~ deep
elongated clos~d end cavity by ~anually draping a ~h~et of
1/8-inch thic~ unbaksd dough over a shape-for~ing malQ metal
~old and cov~ring ik with another shape-confor~ing ~emale me~al
mold that was l/4~inch all-arvund larger than th~ male ~old,
thus allowing th~ inch sheet o~ dough between th~ tWQ metal
~old~ to doubl~ in ~Aickne~ to approximately l/~-inch, With
this ~ethod, m~an~, and manually operat~d apparatu~, the ~emale
mold ~imply r~t~d unpr~ured upon th~ dough and wa~ ~ree to
mov0 upw~rd a~ th~ buking dough expanded and rose u~wardly from
~ha h~t o~ bakiny. ~ecæuse the operations wer~ ~anual ~his
production ~ not pra ti~al for the large-volume l~w-cost
production ~ethods necessary for larg~cale ~ale~ in the
marketplac~. In addition, the unpr~$sured P~le ~old on top of
the baking dough produced unpredictabl~ and und~irabl~
non-unifor~ shape~, wa}l thicknes~e , tex~ure~, and sur~ace
colors, in the f inished-baked ~oat~ Bun. The re~ult was a
finish~d product that wa~ not acceptablQ or larg~-~cale
commercial production and sale in a sophi~tic~ted ~ark~kplace
that demand~ an attractive uniformity in the goods it buy~.
It was not until 1991 that I ~olved th~ proble~s
created by bread~type dough for use with frankfur~er~ in the
Boat~ Bun by ~iscovery of unique and prac~ical me~hods and means
--3--
for larga-~cale production to ~hape and bake my ~oa~ ~un. The
~ollowing disclosur~ and ob-jectiv~ o~ this invention show new
and uniqu~ baking ~thods, mean~, and apparatu3e in the
commercial baking industry. ~ut the very uniqueness o~ the Boa~
Bun brought on unexpectably severe problems unique in both kind
anâdmagnitud~.
The Uni~ue Pr~blem~ o~ Sh~pin~an~ ~aXing t~ ~oat~ Bun
The unique d~si~n created s~v~ral uniqu~ shaping and
baking problem~; problems never before encountered and/or solved
by the baking industry; especially the proble~ requ~ring the
si~ulta~eous shaping and baking of the dough unaer sealed high
pras~ure~ within a male/femal~ dis-~et.
In dev~loping this invention ~or shaping and baking the
Boat~ Bun it ~ventually b~came appar~nt that several dstailed
ob~cti~es had to b~ achieved if the several proble~s within the
overall shaping and baking proble~ were to be ~olved; and that
they all had to b~ 301ved in-co~ina~ion with practical ~ethod~,
means, and apparatuses ~or large-scal~ production, ~nd thu~ for
it to b2 a co~orci~l succ~s~ in thQ marketpl~ce. All o~ these
ob~ectlvo~ are dQ~cribsd and developed herein.
Th~ ov~rall obj~ctiv~ of thi~ invention i~ to provide
th~ basic ~Qthod~, ~ean~, and apparatus~ for large scale
commercial production o~ ~y ~oat~ Bun container mad~ with a
special-formulated bread-typ~ ~lour dough.
By th~ word '9basicl' I mean tho~ m~thods, ~ans, and
apparatuses tha~ underlie this invention' unique individual
detail~ covering ~lour formula, baking pressure~ and ~echanical
move~ents of on-line ~tations necessary for the op~ration of this
invention. I do not include the method~ and m~an~ ~or actually
fa~tening said individual details on~o th~ moving belts or chains
that convey the~ along a production lln~ through a baklng oven.
Such fastening nor~ally involves old ar~. Such details I leave
to the option o~ the practitioner o~ thi3 invention.
--4--
To achiav~ both ths ovQrall ob~ctiv~ and th~ sQvera
~pecific, detailed, ancillary, and underlying objectives
necessary to achieve the overall objective, th~ two mo~t
important underlying objective~ are dough formulation and baking
under high pressures. Control of thes~ two underlying
objectives directly af~ect all the other ancillary objectiYes of
thi~ invention.
Obi~ctives of th~ I~vention
1. Methods, Means, and Apparatuses to Produce
the Exemplary Boat~ Bun Speci~icaticn~ Fonming
~n Open~Top Cubic Dim~n~ioned Edibla Container with
Thi~ible Wall3, a _Dee~l~n~ted cavitY ~nd Clos~d ~nd~
. My ~oat~ ~un may be o~ any length, width and depth
depending on the demand~ o~ the marketplace. For thi~ invention
its exemplary specifications ar~ an interior 6-inch length,
1-1/4 inche~ width, l-inch depth to accom~odate the 6-inch
len~th and 3/4 inch diameter of a ~tandard bun-length
frankfurter and it~ dressings. It~ walls are an exe~plary
unifor~ thinn~s~ o~ approximately 1~4 inch, and ar~
exc~ptionally ~lexible without brea~ing. No other edible
cont~in~r h~ ~v~r ~en comm~rcially made or mark~t~d having
the~e ~xe~plary sp2ci~ication~ ~or th~ Boat~ ~un oP this
invention. It i~ thore~ore an obje~tive to produc~ said
exempl~ry Boat0 Bun ~peci~ications.
2. An Ex~mplary Dough ~or~ulation
That Provides Boat~ Bun Walls ~hat Combln~
Ex~ePtionai ~hinness. ~ iP~litY ~ $~x~n~t~
~ he practitioner of this lnvention should be aware of
the i~portant roles of both yea~t and a high gluten content in
the dough formula to obtain the d~sirablQ objectiv~s o~
thinne~, flexility and ~tr2ngth for the Boat~ Bun'~ walls.
Having exceptional thi.nnes~ and flexibility on the one hand, and
-5-
2 a ~
exc¢ptional ~trength on th~ oth~r hand, is an in-opposition and
paradoxical co~bination of qualiti~ The qualiti~ o~
exceptional thinness and flexibility would normally re~uc~ the
strength of a bun'~ walls. Thi3 would b~ unde~irabl~ for the
Boat~ Bun. Becaus~ o~ thinne 3 and flexibility th~ need for
uni~ue ~trength 1~ disproportiQnately gr~ater ~han it i~ for any
prior axt bun, and it i~ achievable through a uniqu~ dough
formulationO
The quality and quantity of th~ ~lour' 5 gluten i~ the
main determinant o~ dough str~ngth. But ~or this ~trength to
function for th~ Boak~ Bun it ~u~t also have a h$gh lev~l of
~lex and bend. one of the function~ of th~ ye~ t i~ to give the
gluten this flex and bend without reducing the r~quired
strength.
When setting up a dough formulation, the practitioner
hould ~odify both the gluten and y~ast to prGduce whatever
~trength i8 rsquired, along with flex and 90~e bend-wi~hout-
breaking, a3 descrlb~d in a compari~on tabl~ b~low. Any
bread-type y~aRt dough~ using p~t~t ~lours can b~ proc~ssed
throu~h th~ method~ and mean~ o~ thi~ invention. But to attain
both th~ ~xceptional ~10x and 3trength gor ~aid Qx~plary use o~
th~ Boa~ Bun ~ho dough ~ormula should giv~ car~ul/~pecial
att~ntion to ~h~ ~orc~ntago~ o~ gluten and y~a9t9 ThQ
p~rcentag~ content o~ both of th~ in th~ dough ~or~ula ~hould
be ~ub~tantially above the l~v21 used ln nor~al br~ad-bun
for~ula~. Flour~ with th~ highe3t gluten cunt~nt plu~ a~ least
3.5% of gluten conc~ntrates ~hould b~ u~Qd and th~ yea~t content
should b~ about 50~ higher than in th~ nor~al/average ~read-bun
Porfflula~.
Table 1 provides an exemplary dough ~ormula showing
~aid high lev~l of both *yeast and *glute~ in the ~ollowing:
2 ~
~Q~
96 bv W~ ht
*Hiyh gluten pa'cent ~lour 49. Oo
Water 24 . 00
*Yea~t 6. 00
Vegetable shortening 6 . 00
Invsrt sugar 5 . 00
~Vital wheat glutan 3 . 50
Egg solid~ 1. 50
Salt ~,~ 50
Caramel colc~r 1. 00
Dou~ pice 1. 00
~ilk whay . go
HB3,9 dQugh cQnditioner/pre~ervativs 60
100. 00%
HB3 dough conditioner/pr~ervativ~ i~ availabl~ fro~
aravan Product~ Co., Inc., Totpwa, New Jer3ey 07512.
41
Th~ pr~otition~r can ~ake con3iderablQ chang0s in th~
ingredient percentage~ ~hown in the exemplary dough formula ~or
those ingredi~nt~ that a~fect. olor, tast2, and i~lavor, provided
they don't affect con~umer acceptability o~ the baked bun.
But change~ in glut~n and yeast should bs don~ very
care~ully b~3c2lu~ they d~t~r~ine t~xtur~ xibility, an
phy~ical str~ngth o~ the baked dolagh. }~ny chang~a should be
don~3 only a~t~r thoroughly t~ting consu~er acceptability in ~he
marketpl~G~. ~y own ~3xperience in the n~arketplaa~ dictates tha~
prudsnc~ and wi~do~ i~ b~st senr~d i~ th6~ perc~ntaqe~ showr
abov~ ~or gluton ~nd y~3ast are r~tain~d.
So that th~ przlc~ion~r may ha~ a r~fQr~nc~ for ~he
paradoxical in-con~bination t~inna~s, îlex~bility, and ~trength
that i~ de~irabl~ ~or th~ Boat~ls Bun I will u~ hlEs v~ry f,amil iar
prior art 3plit: bu~ to illustrate ~h~ co~pari~on.
Table 2 illu~trat~ th~ compara~iv~ wall differences
by:
a~ U~ing a PQ10UZe ~odel ~-T ~or~ion rod to measure in
avoirdupoi~ ounce~ ~he break-apar~ streng~h und~r pull~apart
pr~ssure~. And,
b. Bending saT~pl~ ~trip1 oP ~3aid wall~ around a 90~
(righ~ angle) corner to measur~ th~ ~xterlt og ~l~xibility be~s~re
breaking .
CQ~ara~iv~ Wall Stren~ an~ ll~Y
Break-~part Strength
~verag~ Wall W~dth o~ Nea~urad By
Th~ckne~ ~l~a~ ~u~o~ Pressure
a.
Prior-art bun1 1~8-inch l-in ::h 2-oz .
Thc Boat 1~, Bun 1/4-inch 1 inch ~-oz.
I,ength o~ Flaxibility Mea~ured by
Wall Sample ng~Q~ Bend. _
b.
Prior-art bun1 1/8-inch 5-inc:h 40-
Th~ Boat~g Bun1/4-inch 5-inch so
Thus, my in-combination paradoxica~l ob~ctive~; of
thinne~ lexlbil ity; and strength ar~ achiev~d wi~h Boat~D Bun
wall~ that are 350% thinner than thQ wall~ of' th~ prior-art
(1~4" v~. 1 1/8~ nd break-ap~rt ~3tren~3th that i3 ~t le~st
t~o-tim~ (100%) gr~a~x a~ mea~ured by both pull-pr~ure~
~4-oz. v~. 2-oz.) and a 125~ greater ~lexibility a~ m~a~ured by
~gl~ b~d gO~ 0-),
3. A Die-S~t, Relea~ably ~Qal2d ~og~h~r to
With~t~nd a Maxi~um o~ 5~-lb~. p~i. IntQrnal
P~e~sure~ ~or Fas~ Shapin~ ~nd Baking Edibl~
Contain~r Walls That ar~ Pr~cision-St~uctur~d
~or Uni~or~ Thinness, Flexibility, and Strength,
~hro~out th~ Entire stxyL~ture of S~ld CQnt ~ ner
To produce a ~rankfurter-cont~nt-holding con~ainer size
~or th2 prior-art hot~dog bun reguireY a 2-oæ. piece of ~ough,
whil~ th~ ~ize ~or the exempla~y/comparative ~rankfurter Boat~
~un r~guir~s a 1.25 oz. pi~ce o~ dough. Table 3 co~pare~ the
processing and baking times for said r~p~c~ive exemplary pieces
o~ dough.
--8
?, i, i~ J L,~
.Table ~
Exemplary Compari~on o~ Dough-Proce~ing/Baking
Procedures and Times Por the Prlor-Art
Elo~ated Split ~un Vçr3us the Boat~ Bun
. TI~E
2.~-oz. 1.25-oz.
Pro~essinq/bak.inq Procedure~Prior-art bun Bo~t~ ~un
Fer~en~ation at 82-F. ~
~60-minute~ 25-minutes
Proofing (~orming) at 107~FJ
Shaping & Baking in 380~F. oven ~0-minutes 13-minutes
ln non-~aaled in sea}ed
pan & cover die-set
Total proce~ingJbaking time80-minut~ 43-minutes
Th~ abov~ exe~plary compari~on graphi~ally shows the
radioal reduction in dough-processing~baking ti~Q o~ the Boat~
Bun v~rsu~ the prior-art split bun that i~ th~ re~ult o~ baking
under maximum of 55-lbs. p5i prsssure. Th~ 55-lbs. p~i maximum
pres~urQ i~ only a practical operating max~mum. At this maximum
the shaping o~ tha ~aking dough i~ compl~te. There is no nePd
for a higher pres~ur~. Howev~r, i~ th~ pra~sure ~hould
inadvertently ~xc~od 55-lb~. p~i, thi3 would not ~lqnl~lcantly
af~ect th~ qu~llty o~ the baked bun.
~ h~ 80-nlnute total tims requir~d by tha prior-art's
co~bined ~er~ntation, proofing, and baklng i8 reduced to
4 3 -minute~ by th~ thod~, means, and app~ratus~ o~ this
invention for producing the Boat ag Bun . This produc~ the
following comparative re~ults-
1. a .75-oz., or 37.5% reduction in dough weight;
2. a 35-1ainutes (60-minO v~. 25-~in~ ) or 58% reduction
in the two combine~ ~unctions of ~erm~nta~ion and proof ing
b~cau~e most of th~se two function~; are faat ~inished within the
sealed pressur~3~ of` said die-set during the 18-minut~ baking
ti~e;
3. a 3~ ~Rinutes, or 46% reductiorl in ~he three overall
combined function~ of fermentation, proofing, and baking;
_g_
2 'j ~
4. all o~ thes~ ~a~or proce~lng reduction~ translate
into ~ub~tantlal overall monetary ~a~ings in op~rating co~ts.
Th~Ae reductions ara obtained through u~ o~ th~ uniqu~ method~,
mean~, and apparatuse~ compri~ing a prQ~ure-seal~d die-set ~or
~haping and baking the di~ensions of th~ Boat~ Bun, a~ de~cribed
in bha next ob;ective and the drawlngs.
Prior-art frankfurter-type split-bun~, and any other
yea-~t-rai~ed bread-type dough bun~ r have never had their doughs
com~ercially proce sed, ~ormed, and baked under positive,
seale~, high preAsure~. Their doughs have alway~ be~n
proces~ed, formed, and baked in open, floating-cover, or
1005a-~itting pan~ or ~ram~ that do not enclo~e the dough
within a sealed ~re3surized spac~. .
Th~ir dough3 ar~ alway~ expo~ed to ~ome oYen
ambient-air te~psra~ure~, and ar~ frQ~ ~o rls~, expand, or
contract whil2 being f~rmented, retardad, proo~ed and baked
within the confino~ o~ their own open and/or non-~eal~d pans ~o
whate~er ~ize, ~hap~, textur~, and wall thic~n~s th~ir
quantity/w~ight o~ dough, and th~ir tim~/temp~ratur~ o~ baking,
produc~s. ~hera i~ no public r2co~d o~ br~ad-typ~ y~a~t raised
dough3 b*ing b~k~d und~r th~ ~eal~d high pre3sures r~uired for
my inv~ntion. Th~ b~king indus*ry appar~ntly ha~ never b~en
con~rontQd ~ith th~ need for, and~or the probl~ of, ~his kind
of baking.
~ ut this n~ed and thi~ proble~ li~8 at th~ heart of
thi~ in~ention. Without th~ con~in~d high pr~ures g~nerated
during the baking of th~ Boat~ Bun naith~r tho individual nor
th~ combined obj~ctive~ of thi~ invention could be achiev@d.
Thu3 the obj~ctive of fa~t forming the Boat0 Bun'~ con~ainer
walls, not only produces time, en~rgy, and ~pac~ ~aving
advantages over th~ prior-ar~, but also the related s~bs~antial
monetary ~avings.
--10 -
~ J~/l
It 1~ theræ~ore an o~ectlvQ o~ ~his invention to shape
and hak~ my contain~r walls withir a ~e~led di2 ~t with
heat-gen~ratad high pre~sure~.
D~c~iption o~ th~ Inven~ion
~ An exe~plification of th~ ~Qthod~, means and their
sQquential st~ps, th~t I have d2vi~Qd ~or shaping and baking the
Boat~ Bun under high pr~ur2 utilizes a hing~d clamping frame
~or rel~asably loc~ing a die-set under baking pr23~ur~ within
said die-set up to 5~ lbY. p8i. A detail~d de~cription o~ said
frame is pre~ent~d in thQ acco~panying drawing9.
Within said die ~et and cla~ping ~ram~ th~
~haping-baking o~ said dough take~ plac~ ac follows:
A di~-~et compri~ing a pair of m~tchi~g and ne~ting
male and female dies formsd ~rom 22 g~ge ~he~t metal or
ther~oplastic, with any standard dough-relea~e agent covering
its dough-contacting ~r~aces, having a unl~or~ open ~paced
r~lationship with an ~xe~plary 1/4 inch b~tw~n ~aid di~3 to
providQ th~ thin unl~or~ wall thickn~ requ~r~d ~or the Boat~
Bun; a piec~ o~ mix~d, non-~erment~d/retard~dOprco~ed, high
gluten, bro~d~typ~ dough, with 6% (b~ tota} dough w~ight) yeast
within its ~or~ula, hæl~ within s~id ~p~c~ ~tw~en ~d di~;
said dou~h-holdlng di~s c~nt¢rad and pr~s~d tightly ~ogeth¢r in
~aid sp~c~d relationship, th~reby spreading out ~aid ~ough
within said ~pac~; and th~n relea~ably locked t~g~ther in a
hinged clamping ~ra~e in po~itive ~eal~d r~lationship to confin~
the optimum intern~l 55-lb~. p~i high pre~uro g~nsr~ted by
a~out 350-F baking heat, wher~by said ~r~su~e/h~at will expand
~aid dough to ~ aid space and ~hape/bake it in about
l~-~inute~; said r~lea ~ble lock b~ing ~pring-loa~@~ ~o provide
int~rnal pres~ure r~ f after it reach8~ a predetermined
pressur~ level under $5-lbs. psi.
2 ~
In an ~xeD~plary proce~ o~ baking, the rapid expansior
o~ th~ ds:~ugh fro~n a quiescent pieca into a complet~d E~oat~, Bun
within said die-set proceeds in the following step~:
B~fore bakinq: a 1 1/4~oz. elongated pi~ce of dough is
d~po~ited into the bottom of the feDIale member o~ th~ di~-set.
Th~n the mal~ member i~ mated and centered within th~ ~emale
ab~r partially ~lal:tening and ~preading th~a dough-piece . o it
occupie~ about 2 o:~ th~ 7- ::u . inch~Ei within 'che 1/4-inch space
between ~aid di~ t. Said dough-vccupied die-set is then
m~chanically ~;ealed by clamping within a spring-loaded
rel~asable locking frame~, and plac~d in th~ baking oven.
Durin~ baking: The axpan~ion of ~aid dough i~ v~ry
~ .
slow during thQ fir~t hal~ oi~ its 18-minute baking time-cycle.
After abollt ~ 2-minutea o~ th~ baking cycle, when th~ dough
reaches about 170 - F., it has a rapid expansion that within about
3-minute3 s~tantially ~ill th~ dough into th~ entlre op~n
~pace within ~aid die-s~t. ~uring the r~maining 3-mimltes o~
baking time, thsa dough r~aches about 3~0-F~, ~h~ pr~s~ure rises
to a pred~ter~in~d lev~l und~r 55-lb3. pBi, the~ dough co~pletes
its expan~lon~ compacted, and ~ully ~hapecl/ba}ced within said
die ~Qt a~ ~XC~88iV~!I int~rnal prQssuro i~ rel$eved by ~aid
~pring-load~d rOE31~a~abl~ lock.
At the end o~ said 18-~inutes shas pin~baklng cycle said
di~-se~ i~ unlo¢ked, ~parated, and ~aid ~e~ale die is ~urned
upsid~ down; whereupon ~aid bak~d 13oat ,~, B~m will ~all out of
~aid di~, ready for packaging and shipping.
It will b~3 under~tood by ~killed practition~rs that
considerabl2 variation~ may be laad~ in th~ Qxe~plary
~pecification~ o~ my invention, a~3 de~cribed above, without
departing from it~ ~pirit or e~sence.,
For example, optional me~hod~ rOr r~31ievirg excessive
internal pres~;ure ::an b~3 ~hrough a seriç~s o~ . 001 inch diameter
hole3 located along ~he 2dges of said ~a~ale die where th~
~amale and mals di~s IZ~Q~, or through pro~ ur~-induced
~eparation o~ the dle-set it~ withisl a 1008e~1y clamped
clampinq ~ra~ through said hole~ or through said
pressura-induced separation o~ said die-set that baked dough,
called fla~hing, can/will extrrude out of ~aid dl~-~et. It $-~ at
~aid hole~ or sf3paration that said ~lashingE~ can become part of
thQ edg~s o~ ~aid baked Boat,!l, Bun. I$ ~aid rlashing~ are
ex~Q~sive, wheth~r through said holQ~ or thrc~ugh ~aid di~-set
separa~ion, they can 2aqily and quickly be trimmed off before
packaging aid shaped/baked Boat x Bun.
The most dif~icult optional m~thod i~ to provide
perf~act, uniform, consist~nt control ov~r all th~ variabl~ that
af~ect th~ int~rnal die-s~t pre ~ure~ durinq th~ baXing
proce3~e~ o~ my Boat0 Bun. These variable~ include dough
formulation and w~ight; the pre-baking teD~perature~3 during
mixinq and cutting; and the baking its~lf. I~ pQrfect control
c:an be attained ov~r said variabl~a~ th~n ~aid baking dough could
i~ill ~a.id di~ t p~r~ectly with a minimum Or pr~uro and no
extruded dough ila~ ing. Th~ e~e~:t would be~ z~n ~V~Il exchange
b~w~en th8 3)aksd dough ~nd the alx ~ithin th~s ~ix~d csbic ~pace
withln l:h~ dl~ ~t2 . ThB a ~ r would ba incorporated into the
air-c~ll structur~ oit the bak~d dough. I~ th~ practitioner of
thi3 in~ention e~anno~ attain ~uch a practical-op~rating perfect
conl:rol oP ~id vari~bl~s, then provi~ion ~or r~ ro~
~laXCQ~3~3iV0 pre~sllre mu~t be mada with m~aln~, ~uch a~ the
sxQ~pl~ry provi~ion di~s::lo~d in thi~ v~antion.
The invention i5 illu~trated in th~ acc:oEIp~nying
drawings and described by the ~ollowing d~ltailç!d explanations oP
the drawing~ wherein my die-se~s are w~lded together in groups
Or PourO Th~ ~equence of the numbered F~gur2~ al~o describe the
~equenc~ of my procs6~ing procedure~
Fig. 1 i~ a per~pective view o~ a dle ~ek A with the
~ale and ~emale member3 separa ed and lying alongside each
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f.~
o~her. The m~le dia~ A-l include paripheral rlange~ l-a and
twelve p~rlpherally-located clip~ 4, weldQd togethex with three
(seen in Fig. 2) straps 3, raady ~or tip-over into and onto four
welded-together ~emale dia~ A-2~ The twelve clip~ keep the male
dies in centered position within the ~our welded-together ~emale
diegO Two tabs 5 welded on the f~alQ die~ ~a~ilitatQ
separation of the ~oat~ ~un-containing di~-sets a~ter baking.
Fig. 2 is a perspective vi~w o~ th0 die-~et with the
mal~ die~ l in elavation above the ~ale dies A-2. The male
dies are welded to three strap~ 3 and ar~ poised ~or insertion
into ~h~ female die~ A 2, which contain ~lnger~ o~ 5-oz.
unbaked.dough b.
Fig. 3 i3 a per~pective view o~ th~ mall~ dies A-1
inserted within the ~emale dies A-2 to ~orm ~our di~ ~sts with
~aid diss centerad and held closad tog~th~r by clips 4, wi~h
unbaked dough (not vis~bl~) in ide the di~-set~.
Fig. 4 i~ a cro~s-section YieW taken along line X X o~
Fig. 3 ~howinq p~rti~lly-baked dough 6 ~illing ~he l/~-inch
pac~ ~-a betw~en the m~le and r~male die~. Thi$ i~ the
condition/po~ition o~ said dough a~t~r about 12-minuts~ in the
baking cyclo~
Fig. 5 i~ a per~p~ctiv~ vi~w o~ th~ di~-~ets ~ within
an open cla~plng-~rame 7, wlth th~ di~-s~ts po~ition~d in
readin~s ~or said clamping-~ra~ to be clo~d ~nd locked ov~r
the~.
Fig. 5-A i~ a p~rspec~ive vi~w o~ cla~plng fra~ 7 in
open po.ition and important member~ o~ ~aid ~rame in both
ssambled and di~assembled view~. ~okQ Y-A, hown assembled
insid~ the circl3 and di~assembled in~ide th~ br~cket, is the
passiv~/~tationary ~emb~r of said ~ram~ locking a~embly and
include3 angl~d shoulder~ x, rece~3e~ y, and pillow-block z.
Fig. 50B ig a p~r~pec~ive horizontal, disas~embled-
from-said frame, view of the insid~ and out~ide of the
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2 9 ~
active/mov@ahle lock~bolt~and~pin ~emb~r~ o~ ~aid ~r~e'~locking a~embly. Pin d i8 po~itioned in ~lot d-1, under
pres~urs from spring d-2, with 9aid pre~ure calibratable and
maintainable at any desired pressure up to 55-lb~. p3i by
ad~ustinq spring pre~sure with adjustable ~cr~w d-3~ Fig. V-~,
encixcled in ellip~a, shows said active/~ov@able member of said
fra~' 3 locking a~s~mbly in vartical po~itlon ~ully assembled
within said frame.
Fig. 5-C i~ a persp~ctive view of both the disassembled
part~ (in bracket) and the assembled part~ V-C ~in circle) o~
the as~e~bly that holds said locking a~embly within aid frame,
co~pri~ing yolk x-l, pillow-block y~l~ and pinion z-l .
Fig. 6 i~ a p~rspectiva ViQW 0~ die-~et~ A in clamped-
locked position within clamping fra~Q 7 with locking pin d in
spring-pressured po~ition locked within rece3s y, with dough
filling the sp~ce (invisib}e) b~tween th~ male and female dies
ready to entQr, bake in~id~, and exit a baking ov~n. When the
pre~urs ~rom th~ ba~ing~axpanding dough with~n the die-sets is
enough to lift pin d out oP r~C~ae~ y, th~n pin d will ~lide
down angled shoulders x whereby ~aid cla~ping ~r~ unlocked
and op~n~d, and ~ald di~ ta, with thei~ ~nclo~d baked dough,
rQ~ovabl~ ~ro~ ~aid cla~ping fra~. .
Fig. 7 i~ a p~rspectiv~ vi~w ~ho~-ing th~ op~ned frame 7
aftar ~aking, with ~alQ di~ remoYed, and bak~d bun 8 lying
within thQ ~emale di~.
Fig. 8 i~ a p~spectiv~ vi~ o~ ~hæ b~ksd bun~ 8 being
tipp~d out of th~ir ~e~al~ die~ A2 b~tto~ ~id~ up,
Fig. 9 i~ a perspective full~cale vi~w of ~y exemplary
bun 8 ~op-side up with-a ~rankfurter 9 r~ iding within said bun.
Whil~ in th~ ~oregoing specifcation a d~tail~d
d~cription of a ~p~ci~ic embodim~n~ of th~ ~ nY~n~ion wa~ set
~orth for the purpose o~ illu~tration, 1~ will be und~rstood
~hat many o~ ~he detail~ herein giv~n may be vari~d con~iderably
by tho~e skilled in th~ art without depar~ing rro~ the spirit
and scope of the invention.
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