Note: Descriptions are shown in the official language in which they were submitted.
CA 02440525 2003-09-11
Atty. Docket No.: 8160.17788-FOR CA
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Patent
A STRUCTURE AND METHOD FOR CUTTING SLABS OF NATURAL
CHEESES INTO SHAPE(S)VIA CUTTING BLADES OF A PATTERN'
SUCH THAT THE SHAPE(S) ARE TESSELLATED OR NESTED
Background of the Invention
This invention relates generally to the
field of cutting patterns out of materials, and
specifically to the cutting of nested, mosaic, or
tessellated patterns from a slab or block of food
product, e.g., cheese.
It is commercially desirable to provide food
products in a variety of shapes that are appealing to
consumers, e.g., cubes, stars, hearts, moons, various
animals, various plants, various representations of
real people or fictional characters, various shapes,
various figures, etc. Typically, the production of such
shapes and designs produces a commercially undesirable
level of waste product, sometimes referred to as trim
or "fines." It is the object of the present invention
to provide for the production of such shapes through
the use of specially designed tooling to provide a
system, by which such food products of various shapes
may be produced with little or no waste product, i.e.,
fines.
Summary of the Invention
The process and system of the present
invention may include pre-cutting a target food product
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into slabs. The slabs produced by this initial cutting step
are within a predetermined size range, i.e., predetermined
range as to height, length and width. After a slab of target
food product is cut so that it is of a size that is within the
predetermined boundary of the predetermined size range it is
introduced to a cutting tool at a predetermined time and at a
predetermined speed.
A cutting tool according to the present invention is
of a predetermined size and includes at least one cutting
blade. The cutting blade preferably includes a cutting edge
having a contour defining a shape that is at least sufficient
to cut a predetermined pattern of tessellated or nested
figures out of the slab of food product.
A preferred cutting tool may be in the form of a flat die
having a laterally extending lattice cutting blade capable of
cutting a predetermined pattern, and may include a knockout
block for removing the cut pieces from the die.
Alternatively, the cutting tool may be in the form of a rotary
cutting tool having a radially extending lattice cutting blade
capable of cutting a predetermined cutting pattern.
The invention, in a broad aspect, seeks to provide an
apparatus for cutting a slab of food product into
predetermined shapes. The apparatus comprises a support
surface upon which a slab of food product can be placed, and a
cutting die located above the support surface, the cutting die
being moveable between a first, raised position and a second,
cutting position. The cutting die has a plurality of
intersecting cutting edges mounted therein which are oriented
essentially orthogonally with respect to the support surface,
the intersecting cutting edges defining a plurality of shapes
located therebetween which shapes fit together in a pattern
with substantially no spaces therebetween. A first drive
device is arranged to move the cutting die from the first,
raised, position to the second, cutting, position, and a feed
device is arranged to feed a slab of food product on the
support surface to a cutting area.
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Description of the Drawings
Figure 1 is a perspective view of the apparatus according
to the present invention.
Figure 2 is an exploded view of the apparatus shown in
Figure 1.
Figure 2A is an enlarged, exploded view similar to
that of Figure 2, but particularly showing the die plate and
knockout block.
Figure 2B is an enlarged, fragmentary, exploded view with
partial cross section of the portion of the die plate and
knockout block shown generally in Figure 2A as
2B.
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Figure 3 is a fragmentary section view of
the apparatus seen in Figures 1 - 2B, taken along line
3 - 3 of Figure 1 and showing the die plate in the
retracted position.
Figure 3A is a fragmentary section view
similar to that of Figure 3, but showing the die plate
in cutting position.
Figure 4 is a side plan view of the
apparatus shown in Figures 1 - 3, but showing the
apparatus in conjunction with an optional cheese block
cutting assembly.
Figure 5 is a side plan view of the
apparatus shown in Figures 1 - 4, and further showing a
pre-sliced slab of food product in ready position
relative the cutting area of the apparatus and prior to
being cut into desired shapes.
Figure 6 is a side plan view similar to
Figure 5, but showing the die plate lowered into
cutting position relative to a slabbed food product.
Figure 6A is an enlarged fragmentary
perspective view of area 6A of Figure 6.
Figure 7 is a side plan view similar to
those of Figures 5 and 6, but showing the die plate
lifting from the cut food product and retracting into
the knockout block, thereby forcing the cut food
product from the die plate.
Figure 8 is a side plan view similar to
those of Figures 5 - 7, but showing the die plate in an
optional, secondary, partially extended position.
Figure 9 is a side plan view similar to
those of Figures 5 - 8, but showing the die plate in a
resting position and retracted into the knockout block.
Figure 10 is a side plan view of an
alternative method and structure of the present
invention including discharge of the cut pieces of food
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product into the interior of a rotary cutting wheel and
the use of pressurized air to remove the cut pieces of
food product.
Figure 11 is a perspective view of another
alternative cutting tool design having removable or
demountable cutting dies as well as open or non-cutting
areas.
Figure 12 is a side view of an alternative
procedure and structure of the present invention.
Figure 13 is a side plan view of another
alternative structure and method of the present
invention.
Figure 14 is a perspective view of yet
another alternative cutting tool arrangement including
a tumbler and a feeder tube through which a
predetermined material, such as a coating material, may
be added to the cut pieces of food product.
Figures 15 through 25 disclose a variety of
alternative cutting patterns into which a cutting edge
may be formed and that may be employed to cut a food
product with minimal or zero waste, with Figures 15A
15E illustrating views of a food product cut according
to the cutting pattern of Figure 15, by way of example.
Detailed Description
Although the disclosure hereof is detailed
and exact to enable those skilled in the art to
practice the invention, the physical embodiments herein
disclosed merely exemplify the invention, which may be
embodied in other specific structure. While the
preferred embodiment has been described, the details
may be changed without departing from the invention,
which is defined by the claims.
The invention may be practiced as
illustrated in the Figures. With particular reference
to Figures 1 - 9 the structure and method of a
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preferred embodiment of the present invention may be
seen. As seen particularly in Figures 4 - 9, slabs 10
of a food product 12, such as cheese, are pre-
positioned and ready for introduction to a cutting die
5 20, having a predetermined cutting pattern. The
predetermined pattern configured of the die 20 is
capable of cutting or stamping an introduced slab 10 of
predetermined thickness into tessellated or nested
figures of food product. See, e.g., Figures 15 - 26,
which show some suggested types of cutting patterns
that could, without limitation, be used.
As shown in Figures 1 - 2B, inclusive, an
apparatus 14 according to the present invention may be
seen. The apparatus 14 as shown is a press type cutter
and preferably utilizes a vertical motion to cut slabs
10 of food product 12 (see Figure 4). The apparatus 14
preferably includes a support workstation 16 for
supporting feeder means, seen herein as a belt-type
conveyer 18 and other apparatus components as will
hereinafter be described. The apparatus 14 further
preferably includes a planar cutting die 20 having a
plurality of laterally extending cutting knives 22 (see
Figures 2A and 2B). The cutting knives 22 are
preferably arranged in a predetermined latticed cutting
pattern 24 corresponding to the shape of food desired.
Since a desired goal of the present invention is to
minimize waste, such as trim or "fines" during a
cutting procedure, a latticed cutting pattern 24
according to the present invention preferably includes
a nested or tessellated configuration.
Seen particularly in Figures 2 through 2B,
the apparatus 14 may further include a knockout block
26. The knockout block 26 is arranged to knock out the
individual cut food products 17 (depicted in Figure 7)
from the cutting die 20 after the slab 10 of food
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product 12 has been cut. To accomplish this task, and
as seen particularly in Figure 2B, the knockout block
26 preferably includes a plurality of downwardly
protruding knockout shapes 27 each having a knockout
surface 28. The knockout surfaces 28 each define a
predetermined perimeter 29. The perimeter 29 of each
knockout surface 28 preferably adjoins and defines a
re-entrant channel 30. The channels 30 form an
interlocking pattern, which preferably corresponds to
the predetermined cutting pattern 24 of the cutting
knives 22. As seen particularly in Figure 3, this
arrangement allows the cutting knives 22 to retract
into the respective channels 30 of the stationary
knockout block 26 when withdrawn between cutting
actions. Further, and as seen in Figure 7, the
knockout surfaces 28 are adapted to urge the cut food
product from the cutting die 20 after cutting. It is
to be understood that while the various Figures depict
knockout surfaces 28 that correspond to the shape of
the desired, finished food shape, other knockout
surface configurations may be envisioned. Minimally,
the knockout surfaces 28 are of at least a shape and
size able to fit inside a respective knife shape
profile, thereby knocking out the cut food 17 from
within the knife perimeter, which perimeter will
hereinafter be described and discussed. Further, the
knockout surfaces 28 may be optionally provided with a
raised or countersunk surface (not shown), to thereby
allow for embossing, stamping, or imprinting the cut
food 17. An example of a cut food 17 having an
embossed portion 120 may be seen in Figures 15 - 15 E,
by way of example.
As may be seen particularly in Figures 2A
and 2B, the individual knockout shapes 29 are
preferably of a predetermined height H. The
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predetermined height H may be of any acceptable height,
but is preferably of a height at least corresponding to
the height H of the cutting knives 22. In particular,
as seen in Figure 3, the individual heights H of each
knockout shape 27 may vary in the staggered pattern
shown. A staggered height pattern provides a more even
force distribution across the cutting die 20 when the
cut food product 17 is forced from the cutting die 20
after cutting (see Figure 7), and thereby having a
greater efficiency of design.
Referring now to Figures 1 - 3, the various
components of a preferred apparatus 14 according to the
present invention may be seen. As mentioned earlier,
the apparatus 14 preferably includes a support
workstation 16. A prime mover, seen as an air operated
cylinder and piston 32 is supported by the workstation.
16. While the various Figures depict an air operated
cylinder and piston 32 as the prime mover, it is within
the province if the present invention to use other
prime movers, such as solenoids, linear servos, cams-or
other known means. A reciprocating, movable operating
cross bar 34 is threadingly connected with an operating
rod 36 extending from the prime mover (as detailed in
Figure 3A). The reciprocating, movable operating cross
bar 34 is attached to at least one vertically operating
traveling member 38, with two, oppositely disposed
traveling members 38 being shown in the Figures. The
vertically operating traveling member 38 further
includes a secondary cross bar 40 having upwardly
extending threaded studs 42. The threaded studs 42 are
adapted to be received by through bores 41 located in
the cutting die 20. The threaded studs 42 are further
adapted to be received and threadingly seated in
threaded apertures 44 formed in the lower ends 46 of a
respective extension 48. The extensions 48 each
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include an upper end 50 having a threaded portion 52 to
be threadingly received by manually operable wing nuts
54. Although other fastening means may be envisioned,
wing nuts 54, as shown, are preferred for ease of
breakdown and setup of new die and knockout
combinations. The upper end 50 is further adapted to
be received by a corresponding through bore 56 in an
upper cross bar 58 and sufficiently extending to be
threadingly received by manually operable wing nuts 54.
While the Figures illustrate a pair of generally
parallel cross bars 58 the invention may be practiced
with other numbers of cross bars 58.
The workstation 16 further includes upright
support posts 60. The support posts preferably each
include an upper end portion 62 adapted to be slidingly
received by through bore 64 of cutting die 20, a first
upper portion 66 adapted to be received by through bore
68 in knockout block 26, and a second, threaded upper
portion 67 to be threadingly received by wing nuts 54.
This arrangement effectively secures the stationary
knockout block 26 to the workstation, while allowing
for vertical movement of the cutting die 20.
As may be seen in the Figures, the upper
pair of parallel cross bars 58 further preferably
includes transversely disposed supports 70, each of
which include a plurality of downwardly extending rod
members 72. The rod members 72 are slidably engaged by
corresponding cooperating apertures 74 (seen
particularly in Figure 2B) in the stationary knockout
block 26 and extend downwardly to rest upon the upper
surface 76 of the cutting die 20. As may be seen
particularly in Figure 6A, the rod members 72
preferably rest upon the upper surface 76 at pre-
selected intersections 78 of the lattice cutting
pattern 24. The rod members 72 provide equal
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distribution of force throughout the top surface 76 of
the cutting die 20 during the cutting process.
Referring now to Figures 4 - 9 the process
and method of the present invention may be seen. As
may be seen particularly in Figure 4, slabs 10 of a
food product 12, such as cheese, are introduced to a
cutting die 20 having a predetermined cutting pattern
24 as discussed previously. The predetermined pattern
24 is capable of cutting an introduced slab 10 into
tessellated or nested figures of food product. See,
e.g., Figures 14 - 26, which show some suggested types
of cutting patterns that could, without limitation, be
used. As seen in Figure 4, slab 10 may be sliced from
a block 12 of cheese, or other acceptable food product,
to a predetermined thickness by a slicing tool 80, as
shown as part of the method, or may be precut prior to
being introduced to the apparatus 14. The slab of food
product 10 is moved by conveyor 18, as shown in the
Figures, or by other means, to a position directly
below a cutting die 20 (shown in Figure 5). The piston
of the prime mover 32 (not seen in this view) moves the
operating cross bar 34 and vertical traveling member 38
and, as seen by the arrows in Figure 6, thereby lowers
the cutting die 20 toward the slab 10. The knives 22
of the cutting die 20 are thereby pressed into the slab
10. As seen in Figure 7, as the cutting die 20 is
retracted into the countersunk channel 30 of knockout
block 26, the now cut food product 17 is urged from the
cutting die 20 by the knockout surfaces 28 (described
earlier with reference to Figure 3).
As may be seen in Figures 8 and 9, the
method of the present invention may preferably further
include the optional step of partially lowering the
cutting die 20 after a first cut has been made, and
retracting the cutting die 20 for a second time into
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the countersunk channel 30 of the knockout block 26.
This optional step ensures removal of all cut food 17
from the cutting die 20 and knockout block 26 prior to
cutting the next incoming slab 10.
With attention to Figure 10, an alternative
embodiment cutting apparatus 90 may be seen. As shown,
slabs 10 of a food product 12, such as cheese, are
introduced to a rotary cutting die 90, having a
predetermined cutting pattern 24 (See Figures 15 - 25,
which show some suggested, non-inclusive types of
cutting patterns that could be used), and a compression
wheel 92. As is further seen, the slab 10 is fed into
a pinch point 94. The compression wheel 92 forces the
slab 10 into the cutting pattern 24 of the cutting
wheel 90. Substantially, the entire slab 10 is cut
into individual pieces 17 as determined by the cutting
pattern 24 that is used; very little or no waste
material, i.e., material that cannot now be packaged,
is produced. The resulting cut pieces 17 may then
either be allowed to fall into the interior 95 of the
cutting wheel 90 and tumble out an end 96 or,
alternatively, may be carried between the cutting
blades 97 of the cutting pattern 24 and discharged
tangentially at a later point in the rotation via any
number of means such as gravity, centrifugal force, an
automated plunger, application of compressed air, etc.
Similarly to the previously described
embodiment, and to ensure that the cutting pattern 24
is in appropriate position, the cheese slabs 10 are
advanced via a conveyor belt 18 that operates at a
predetermined speed. As noted previously the cheese
slabs 10 all fall within a predetermined size range. A
sensor 98 may be used to ascertain the position of the
cheese slab 10. An encoder 99 is preferably
communicatively coupled to servomotors 100 that are
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operatively coupled to both the cutting wheel 90 and
the compression wheel 92. The encoder 99 tells the
servomotors 100 the speed of the belt 18 and thus the
speed of the slab 10. The servomotors 100 then match
the speed of the belt 18. The servomotors 100 are
capable of adjusting the speed of the cutting wheel 90
and the compression wheel 92 to match the speed of the
cheese slab 10. The cutting pattern 24 of the cutting
wheel 90 is at a known starting position. The
servomotors 100 preferably cause both the cutting wheel
90 and the compression wheel 92 to rotate at a speed
that matches the speed of the slab 10 and at a time
that cutting pattern 24 is in position to cut the slab
10. Alignment with both the compression wheel 92 and
the cutting wheel 90 is preferably maintained by use of
side belts (not shown). In this manner slab 10 after
slab 10 may be cut and the resulting pieces 17
packaged.
A specific example of an alternative
embodiment of the present invention may be seen in
Figure 11. The alternative embodiment shown may
include a cutting wheel 90 comprised of first and
second cutting sections 102 and first and second non-
cutting sections 104. The first cutting section 102
will cut a particular pattern out of a first slab 10 of
predetermined food product, such as cheese. The first
non-cutting section 104 will sequentially follow the
first cutting section 102 to allow for discharge of the
now cut pieces 17 of the first slab 10 of cheese as
well as separation from the subsequent type of cheese
slab 10 entering the second cutting section 102. The
non-cutting sections 104 allow the cut pieces 17 to
fall through for packaging.
Another alternative embodiment may employ
the use of a cutting wheel 90 having first and second
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cutting sections 102 in conjunction with a compression
belt (not shown) instead of a compression wheel 92 as
illustrated.
Alternatively, and as seen in Figure 12, the
cutting wheel 90 may be replaced by a reciprocating
cutting plate 106 having a cutting pattern 24 (not
shown). The cutting plate 106 preferably matches the
speed of the slab 10 advanced from belt 18 and slides
the slab 10 under a compression wheel 92 whereby slab
10 would be forced onto and through cutting pattern 24
producing cut pieces 17 with minimal or no waste.
As seen in Figure 13, a vented belt 110 may
be substituted for belt 18 and a vacuum chamber 112
used to apply a negative pressure to hold the slab 10
down and against belt 110 during and after the
application of a reciprocating cutting head 90a.
Thereby holding the cut pieces 17 in place on the belt
110 until after they have been advanced past the
reciprocating cutting head 90a.
Another arrangement may be seen in Figure
14. Here, a rotary cutting tool 90 may include a
cutting pattern portion 24 and a tumbler 114. The cut
pieces (not shown in this view) are allowed to fall
into the interior 95 of the tool 90 wherein a feeder
116 may introduce a coating such as an anti-caking
agent, for example (not shown) to the cut pieces 17.
The foregoing is considered as illustrative
only of the principles of the invention. Furthermore,
since numerous modifications and changes will readily
occur to those skilled in the art, it is not desired to
limit the invention to the exact construction and
operation shown and described. While the preferred
embodiment has been described, the details may be
changed without departing from the invention, which is
defined by the claims.
