Note: Descriptions are shown in the official language in which they were submitted.
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FLEXIBLE BAKEWARE HAVING A MULTI-PIECE CARRIER SYSTEM
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] This invention relates generally to flexible bakeware and in particular
to an
improved flexible bakeware container that is made from a novel compound and
includes a
carrier for assisting a user in carrying the bakeware container.
2. Description of Related Art
[0002] Flexible bakeware is typically made from a silicone rubber formulation.
The
silicone composition prevents strong odors from being transferred to the food,
yet provides a
tough, temperature resistant material that, due to its flexibility, allows
food to be removed
more easily than with traditional bakeware. One downside to using a silicone
composition
for bakeware is that the flexibility of the material makes it difficult to
handle. The bakeware
cannot be easily carried with one hand. Instead, it must be fully supported
under its bottom
surface, and most users simply place a metal cooking sheet or other rigid pan
underneath the
bakeware to transfer the bakeware to and from the oven. This solution is
impractical because
the presence of a solid sheet of metal underneath the flexible bakeware can
provide
inconsistent (and uneven) balcing of the food product contained by the
bakeware. More
specifically, the sides and top of the bakeware experience convective heating
from the hot air
within the oven. The bottom of the bakeware experiences conductive heating
since it is in
direct contact with the solid metal cooking sheet. This difference in heating
methods can
cause uneven cooking of the food product. The inconvenience of using a cooking
sheet to
transport flexible bakeware is also a drawback.
[00031 A need therefore exists for an apparatus that could be used in
conjunction with
a flexible baking container that would permit easy transport of the baking
container. A need
further exists for an apparatus that could be incorporated into the flexible
baking container so
that together the device and bakeware are a self-contained unit. Still another
need exists for
an apparatus that can be readily removed from the baking container
periodically for cleaning
and storage.
[0004] Flexible bakeware also experiences release problems with certain foods.
Compared to conventional non-flexible bakeware, it is often easier to remove
foods from
flexible bakeware because the basin containing the food product can be turned
inside out.
However, with certain foods such as muffins, cakes, or breads, residue from
the foods may
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remain stuck to the flexible bakeware, thereby causing an uneven and
unattractive outer
surface on the food product following removal from the bakeware.
[0005] One solution to the problem of food release is to pre-lubricate a
baking
container with cooking spray, cooking oil, or flour. While this can prevent
food from
sticking to baking containers, the solution is undesirable because it involves
additional steps
in cooking the food (i.e. the step of pre-lubricating) and requires additional
cooking supplies
(i.e. the spray, oil, or flour). Another drawback is that the use of oils or
flour can alter the
taste and texture of the baked food product.
[0006] A need therefore exists for flexible bakeware that has improved food
release
qualities as compared to currently available flexible bakeware. A need further
exists for a
compound that can be easily and inexpensively manufactured into flexible
bakeware. The
compound should be non-toxic and should not impart an odor or taste to food
products
prepared in the bakeware.
BRIEF SUMMARY OF THE INVENTION
[0007] The problems presented by existing flexible bakeware are solved by the
present invention. An elastomeric baking container is provided that includes a
basin having a
first carrier member disposed in an upper portion of the basin. A second
carrier member is
disposed in the upper portion of the basin such that the second carrier member
is capable of
movement relative to the first carrier member.
[0008] A flexible baking container according to the principles of the present
invention
includes a basin having at least one wall and a floor at a first end of the
wall. A shoulder
surrounds at least a portion of the basin, and the shoulder is attached to a
second end of the
wall opposite the floor. A receiving channel disposed within the shoulder, and
a first and a
second carrier member are received by the receiving channel. The second
carrier member is
at least partially spaced apart from the first carrier member to allow
movement of the second
carrier member relative to the first carrier member.
[0009] A bakeware apparatus is further provided that includes an elastomeric
baking
container having a basin and a shoulder surrounding at least a portion of the
basin. The
bakeware apparatus further includes a carrier having a lower support member
pivotally
attached to an upper support member. The carrier is movable between a closed
position in
which the shoulder of the baking container is held between the upper and lower
support
members and an open position in which the baking container can be removed from
between
the upper and lower support members.
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[0010] Another balceware apparatus according to the principles of the present
invention includes a plurality of elastomeric baking containers, each having a
basin formed
from at least one wall connected at one end to a floor and each baking
container further
having a shoulder near an end of the wall opposite the floor and surrounding
at least a portion
of the basin. The bakeware apparatus further includes a carrier having a lower
support
member pivotally attached to an upper support member. The lower support member
is
formed from a substantially planar plate and includes a plurality of lower
apertures. The
upper support member is formed from a substantially planar plate and includes
a plurality of
upper apertures. At least one of the lower apertures is capable of receiving
one of the baking
containers such that the basin of the baking container passes through the
lower aperture and
the shoulder contacts the lower support member. The basin of each baking
container is
substantially aligned with one of the upper apertures and the shoulder
contacts the upper
support member when the carrier is in a closed position.
[0011] A bakeware apparatus is further provided that includes an elastomeric
baking
container having a basin formed by at least one wall integrally connected to a
floor. The
bakeware apparatus further includes at least one carrier member disposed
within a receiving
channel in an upper portion of the wall opposite the floor.
[0012] A bakeware apparatus is further provided that includes a basin having
at least
one wall attached at a first end to a floor. A shoulder surrounds at least a
portion of the basin
and is attached to a second end of the wall opposite the floor. The shoulder
includes one of a
tab and an attachment aperture disposed on the shoulder. The bakeware
apparatus further
includes a carrier having the other of the tab and the attachment aperture to
engage the one of
the tab and the attachment aperture on the shoulder when the carrier is placed
into
engagement with the shoulder.
[0013] The baking container of the present invention may be made from a
compound
including a methyl vinyl silicone polymer from about 40 to 70 weight percent,
a filler from
about 5 to 50 weight percent, a cross-linking agent from about 0.1 to 5 weight
percent, and
polytetrafluoroethylene from about 0.1 to 15 weight percent. In a preferred
embodiment, the
polytetrafluoroethylene is present in an amount of about 6 percent, and the
cross-linking
agent is chloro platanic acid.
[0014] Other objects, features, and advantages of the present invention will
become
apparent with reference to the drawings and detailed description that follow.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 depicts a perspective view of a flexible bakeware carrier for a
plurality
of flexible muffin cups according to a preferred embodiment of the present
invention;
[0016] FIG. 2 illustrates a top view of the flexible bakeware carrier of FIG.
1;
[0017] FIG. 3 depicts a cross-sectional front view of the flexible bakeware
carrier of
FIG. 2 taken at III-III;
[0018] FIG. 4 illustrates an enlarged front view of the of flexible bakeware
carrier of
FIG. 3 taken at Detail IV;
[0019] FIG. 5 depicts a cross-sectional front view of a flexible muffin cup
according
to a preferred embodiment of the present invention, the muffin cup designed
for use with the
flexible bakeware carrier of FIG. 1;
[0020] FIG. 6 illustrates an enlarged front view of the flexible muffin cup of
FIG. 5
taken at Detail VI;
[0021] FIG. 7 depicts an enlarged front view of a flexible muffin cup
according to an
alternative embodiment of the present invention, the view being taken at an
area of the
flexible muffin cup similar to that shown in FIG. 6;
[0022] FIG. 8 illustrates a perspective view of a flexible bakeware carrier
for a
plurality of flexible muffin cups according to an alternative embodiment of
the present
invention;
[0023] FIG. 9 depicts a top view of a rectangular, flexible bakeware according
to a
preferred embodiment of the present invention;
[0024] FIG. 10 illustrates a cross-sectional front view of the rectangular,
flexible
bakeware of FIG. 9 taken at X-X;
[0025] FIG. 11 depicts an enlarged front view of the rectangular, flexible
bakeware of
FIG. 10 taken at Detail XI;
[0026] FIG. 12 illustrates a cross-sectional top view of the rectangular,
flexible
bakeware of FIG. 10 taken at XII-XII;
[0027] FIG. 13 depicts a top view of a flexible bakeware carrier according to
a
preferred embodiment of the preferred invention, the carrier designed for use
with the flexible
bakeware of FIG. 9;
[0028] FIG. 14 illustrates a top view of a flexible bakeware carrier according
to an
alternative embodiment of the present invention;
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[0029] FIG. 15 depicts a top view of a rectangular, flexible balceware
according to an
alternative embodiment of the present invention, the balceware designed for
use with the
carrier of FIG. 14;
[0030] FIG. 16 illustrates a cross-sectional front view of the rectangular,
flexible
bakeware of FIG. 15 taken at XVI-XVI;
[0031] FIG. 17 depicts an enlarged front view of the rectangular, flexible
bakeware of
FIG. 16 taken at Detail XVII;
[0032] FIG. 18 illustrates a top view of a round, flexible bakeware according
to a
preferred embodiment of the present invention;
[0033] FIG. 19 depicts a cross-sectional front view of the round, flexible
bakeware of
FIG. 18 taken at XIX-XIX;
[0034] FIG. 20 illustrates an enlarged front view of the round, flexible
bakeware of
FIG. 19 taken at Detail XX;
[0035] FIG. 21 depicts a cross-sectional top view of the round, flexible
bakeware of
FIG. 19 taken at XXI-XXI;
[0036] FIG. 22 illustrates a top view of a flexible bakeware carrier according
to a
preferred embodiment of the present invention, the carrier designed for use
with the round,
flexible bakeware of FIG. 18;
[0037] FIG. 23 depicts a top view of a flexible bakeware carrier according to
an
alternative embodiment of the present invention;
[0038] FIG. 24 illustrates a perspective view of a round, flexible bakeware
according
to an alternative embodiment of the present invention, the flexible bakeware
designed for use
with the flexible bakeware carrier of FIG. 23;
[0039] FIG. 25 depicts a cross-sectional front view of the round, flexible
bakeware of
FIG. 24;
[0040] FIG. 26 illustrates an enlarged front view of the round, flexible
bakeware of
FIG. 25 taken at Detail XVI;
[0041] FIG. 27 depicts a flow chart of a method of baking a food product
according to
the present invention;
[0042] FIG. 28 illustrates a perspective view of a bakeware apparatus having a
flexible baking container and a carrier, the carrier having an upper support
member and a
lower support member according to principles of the present invention;
[0043] FIG. 29 depicts a bottom view of the lower support member of FIG. 28;
[0044] FIG. 30 illustrates a bottom view of the upper support member of FIG.
28;
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[0045] FIG. 31 depicts a perspective view of the flexible baking container of
FIG. 28;
[0046] FIG. 32 illustrates a cross-sectional side view of the flexible baking
container
of FIG. 28;
[0047] FIG. 33 depicts a perspective view of a bakeware apparatus having a
flexible
baking container, a first carrier member, and a second carrier member
according to the
principles of the present invention, the first and second carrier members
being partially
shown in hidden lines;
[0048] FIG. 34 illustrates a top view of the bakeware apparatus of FIG. 33;
[0049] FIG. 35 depicts a perspective view of a bakeware apparatus having a
flexible
baking container and a carrier according to the principles of the present
invention;
[0050] FIG. 36 illustrates a top view of the bakeware apparatus of FIG. 35;
[0051] FIG. 37 depicts a cross-sectional side view of the bakeware apparatus
of FIG.
36 taken at XXXVII-XXXVII;
[0052] FIG. 38 illustrates an enlarged cross-sectional side view of the
flexible baking
container and carrier of FIG. 37 taken at Detail XXXVIII;
[0053] FIG. 39 depicts a cross-sectional side view of a bakeware apparatus
having a
flexible baking container and a carrier according the principles of the
present invention, the
view being similar to that of FIG. 37;
[0054] FIG. 40 illustrates an enlarged cross-sectional side view of the
flexible baking
container and carrier of FIG. 39 taken at Detail XL;
[0055] FIG. 41 depicts a perspective view of a bakeware apparatus having a
flexible
baking container and a carrier according to the principles of the present
invention;
[0056] FIG. 42 illustrates a top view of the bakeware apparatus of FIG. 41;
[0057] FIG. 43 depicts a cross-sectional front view of the bakeware apparatus
of FIG.
42 taken at XLIII-XLIII;
[0058] FIG. 44 illustrates an enlarged cross-sectional front view of the
flexible baking
container and carrier of FIG. 43 taken at Detail XLIV;
[0059] FIG. 45 depicts a cross-sectional front view of a bakeware apparatus
having a
flexible baking container and a carrier according the principles of the
present invention, the
view being similar to that of FIG. 43;
[0060] FIG. 46 illustrates an enlarged cross-sectional front view of the
flexible baking
container and carrier of FIG. 45 taken at Detail XLVI;
[0061] FIG. 47 depicts a perspective view of a bakeware apparatus having a
flexible
baking container and a carrier according to the principles of the present
invention;
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[0062] FIG. 48 illustrates a top view of the bakeware apparatus of FIG. 47;
[0063] FIG. 49 depicts a cross-sectional side view of the bakeware apparatus
of FIG.
48 talcen at XLIX-XLIX; and
[0064] FIG. 50 illustrates an enlarged cross-sectional side view of the
flexible baking
container and carrier of FIG. 49 taken at Detail L.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0065] In the following detailed description of the preferred embodiments,
reference
is made to the accompanying drawings which form a part hereof, and in which is
shown by
way of illustration specific preferred embodiments in which the invention may
be practiced.
These embodiments are described in sufficient detail to enable those skilled
in the art to
practice the invention, and it is understood that other embodiments may be
utilized and that
logical mechanical, structural, and chemical changes may be made without
departing from
the spirit or scope of the invention. To avoid detail not necessary to enable
those skilled in
the art to practice the invention, the description may omit certain
information known to those
skilled in the art. The following detailed description is, therefore, not to
be taken in a limiting
sense, and the scope of the present invention is defined only by the appended
claims.
[0066] In describing the present invention, the term "elastomer" refers
generally to a
polymeric material that has rubberlike properties. More specifically, most
elastomers have
elongation rates greater than 100% and a significant amount of resilience. The
resilience of a
material refers to the material's ability to recover from an elastic
deformation. Examples of
elastomers could include, but are not limited to, natural rubbers,
polyisoprene, styrene
butadiene rubber, chloroprene rubber, polybutadiene, nitrile rubber, butyl
rubber, ethylene
propylene rubber, ethylene propylene diene monomer, chlorosulfonated
polyethylene,
polysulfide rubber, polyurethane, and silicones. 1
[0067] The term "flexible" refers to an object or material that is able to be
bent or
flexed. The use of the terin flexible in connection with a material or
balceware of the present
invention generally refers to a material or bakeware made from an elastomer or
otlier material
that allows the container portion, or basin, of the bakeware to be at least
partially turned
inside out without plastic deformation of the material.
[0068] Referring to FIGS. 1-4, a carrier 11 according to the principles of the
present
invention is illustrated. The carrier apparatus 11 is used in conjunction with
flexible muffin
cups. Carrier 11 is a substantially rigid, flat plate made from either metal
or temperature-
resistant plastic. Carrier 11 includes a plurality of apertures 13, each
adapted to receive a
flexible muffin cup. Carrier 11 is preferably rectangular in shape with a
chamfer 21 at each
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corner of the carrier. Carrier 11 is preferably made from brushed stainless
steel, and all
perimeter edges 23 of the carrier 11 have been rolled to form a perimeter lip
25 (see FIG. 4).
Similarly, the edges 29 of apertures 13 have also been rolled to form
perimeter lips 31. By
rolling the exposed edges 23, 25 of the carrier 11, the sharpness of the edges
is eliminated.
Carrier 11 also includes a hanger hole 33 at one end of the carrier 11 for
allowing the carrier
to be hung on a kitchen wall.
[0069] Referring to FIGS. 5 and 6, a flexible baking container, or muffin cup
41,
according to the principles of the present invention includes a basin 43
formed by a
substantially cylindrical, tapering wall 44 integrally connected to a floor
46. One end of wall
44 terminates in a shoulder 45, the shoulder having a receiving channel 47.
Receiving
channel 47 preferably includes a depression 49 that is adapted to receive the
perimeter lip 31
of carrier 11. In order to obtain optimum flexibility and release, the wall
thickness of each
muffin cup should be between 0.020 and 0.100 inches. Preferably, the wall
thickness is
0.050-0.075 inches.
[0070] In operation, each aperture 13 on carrier 11 receives a muffin cup 41
such that
a portion of the carrier 11 fits within receiving channel 47. When installed,
the perimeter lip
31 of the carrier 11 is firmly seated in the depression 49 of the receiving
channel 47. The
engagement of the lip 31 by depression 49 more firmly secures the muffin cups
41 on the
carrier and prevents accidental or inadvertent disengagement of the muffin
cups 41 and the
carrier 11.
[0071] The carrier 11 provides rigidity to the muffin cups 41 in an area
around each
shoulder 45 and allows a user to carry the flexible muffin cups 15 with one
hand. The
flexibility of the muffin cups 41 allows a user to easily remove the cups from
the carrier 11.
The removal of the muffin cups could aid a user in removing food from the
muffin cup,
although it is not necessary to remove the cup to effectuate release of a food
product. The
ease with which the muffin cups can be removed also promotes the use of muffin
cups having
different shapes and depths. For example, a muffin cup having a basin 17 that
is heart shaped
may be used to bake heart-shaped muffins on Valentine's Day. Other possible
shapes include
without limitation stars, clover leaves, squares, triangles, and diamonds.
[0072] Referring to FIGS. 7 and 8, a muffin cup 51 and a carrier 61 according
to the
principles of the present invention are illustrated. Muffin cup 51 is similar
to muffin cup 41
and includes a basin 53 formed by a substantially cylindrical, tapering wall
54 connected to a
floor (not shown) at one end and terminating in a shoulder 55 at another end.
Shoulder 55
includes a receiving channel 57, but unlike muffin cup 41, does not include a
depression 49.
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[0073] Muffin cup 51 is designed for use with a carrier such as carrier 11, or
preferably carrier 61. Referring to FIG. 8, carrier 61 is a rectangular, flat
plate made from
metal or temperature-resistant plastic. Carrier 61 includes a plurality of
apertures 63 for
receiving muffin cups 51. The primary difference between carrier 61 and
carrier 11 (FIGS.
1-4) is that carrier 61 does not include rolled lips at perimeter edges 65 or
edges 67 of the
apertures. The lack of a lip at edges 67 allows the carrier 11 to better mate
with muffin cup
61, which includes no depression in receiving channe157.
[0074] Referring to FIGS. 9-12, a rectangular, flexible baking container 111
according to the principles of the present invention includes a basin 112
formed by a pair of
major walls 113 and a pair of minor walls 114, the walls 113, 114 being
integrally joined to
each other and at one end to a floor 115. A shoulder 117 is formed at an end
of the walls 113,
114 opposite floor 115, the shoulder 117 extending completely around the
perimeter of the
baking container 111. Shoulder 117 includes an outer surface 121, an inner
surface 122, an
upper surface 123, and a lower surface 125. A receiving channel 131 having a
circular cross
section is disposed in the shoulder 117 with an entry slot 135 positioned
between the lower
surface 125 of the shoulder 117 and the receiving channel 131. In the
preferred embodiment,
the entry slot 135 is disposed adjacent the lower surface 125 (as shown in
FIG. 11), but it is
conceivable that the entry slot 135 could be disposed adjacent the outer
surface 121, the inner
surface 122, or the upper surface 123.
[0075] Referring more specifically to FIG. 12, the receiving channel 131 and
entry
slot 135 are not continuous around the entire perimeter of the flexible baking
container 111.
Instead, the receiving channel 131 includes a central portion 141 that runs
continuously in the
shoulder 117 adjacent each major wall 113. As the receiving channel 131
approaches corner
portions 151 of the shoulder 117, a turning portion 143 of the receiving
channel 131 follows
the shoulder around the corner portion 151. An exit portion 145 of the
receiving channel then
turns in a direction opposite minor walls 114 and exits the outer surface 121
of the shoulder
117. Because of the discontinuous nature of the receiving channel 131, the
baking container
111 actually contains a pair of receiving channels 131 as illustrated in FIG.
12.
[0076] The preferred location of the central portion 141 of the receiving
channel 131
is in the shoulder 117 adjacent each major wall 113. This configuration
provides the most
support for the carrier that is received by the receiving channel 131
(explained in more detail
below). However, a person of ordinary skill in the art will recognize that the
central portion
141 of each receiving channel 131 could instead be located in the shoulder
adjacent each
minor wall 114.
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[0077] Referring to FIG. 13, a carrier 161 according to the principles of the
present
invention is used in conjunction with flexible baking container 111. Carrier
161 is formed by
a substantially rigid rod having a substantially circular cross section and
made of metal or
temperature-resistant plastic. Preferably, the material composition of the rod
is 304 stainless
steel. Carrier 161 includes a pair of central stays 165 that are substantially
parallel to one
another and are joined at each end to an arcuate stay 167. An end of each
arcuate stay 167 is
joined to one end of a handle 169. Together, the pair of central stays 165,
the four arcuate
stays 167, and the pair of handles 169 form a closed loop. The shape and
length of the
central stays and the arcuate stays closely approximate those of central
portion 141 and
turning portion 143 of the receiving channel 131. Preferably, the central
stays 165, arcuate
stays 167, and handles 169 are welded together from stainless steel rods, but
the carrier 161
could be formed using any other suitable manufacturing techniques known to
those of
ordinary skill in the art.
[0078] In operation, carrier 161 is received by flexible baking container 111
by
inserting the centrals stays 165 and arcuate stays 167 through the entry slot
135 of the baking
container 111 and into the receiving channel 131. The flexible properties of
the baking
container 111 allow the shoulder 117 to bend such that the entry slot 135 is
temporarily
enlarged to accommodate the carrier 161 as it passes through the entry slot
135 and into the
receiving channel 131. After the central stays 165 are positioned within the
central portions
141 of the receiving channels 131 and the arcuate stays 167 are positioned
within the turning
portions 143 of the receiving channels 131, the shoulder 117 elastically
returns to its original
shape. With the shoulder in a"non-deformed" shape, the entry slot 135 is again
smaller than
the receiving channel 131, which secures carrier 161 within the receiving
channel 131.
[0079] With the carrier 161 installed in the receiving channel 13 l, a portion
of the
handle 169 is disposed within the exit portion 145 of the receiving channel,
but the majority
of the handle 169 is located outside the walls of the flexible baking
container 111. Handle
169 enables a user of the flexible baking container 111 to easily lift and
carry the baking
container 111 by holding either one or both handles on that portion of the
handle 169 that
protrudes from the baking container.
[0080] The carrier 161 provides rigidity to the flexible baking container 111
in an
area around each shoulder 117 and allows a user to more easily lift and carry
the baking
container 111. The flexibility of the baking container 111 allows a user to
easily remove the
carrier 161 from the receiving channel 131 of the baking container 111. The
removal of the
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carrier 161 could aid a user in removing food from the baking container 111,
although it is
not necessary to remove the carrier 161 to effectuate release of a food
product.
[0081] Referring to FIGS. 14-17, a rectangular, flexible baking container 171
according to the principles of the present invention includes a basin 172
formed by a pair of
major walls 173 and a pair of minor walls 174, the walls 173, 174 being
integrally joined to
each other and at one end to a floor 175. A shoulder 177 is formed at an end
of the walls 173,
174 opposite floor 175, the shoulder 177 extending completely around the
perimeter of the
baking container 171. Shoulder 177 includes an outer surface 181, an inner
surface 182, an
upper surface 183, and a lower surface 185. A receiving channel 191 having a
rectangular
cross section is disposed in the shoulder 177 with an entry slot 195
positioned between the
lower surface 185 of the shoulder 177 and the receiving channel 191. In the
preferred
embodiment, the entry slot 195 is disposed adjacent the lower surface 185 (as
shown in FIG.
17), but it is conceivable that the entry slot 195 could be disposed adjacent
the outer surface
181, the inner surface 182, or the upper surface 183.
[0082] The receiving channel 191 and entry slot 195 are preferably continuous
around
the entire perimeter of the flexible baking container 171. However, it is
conceivable that a
discontinuous receiving channel 191 and entry slot 195 could be used similar
to those of
baking container 111 (see FIG. 12).
[0083] Referring more specifically to FIG. 14, a carrier 201 according to the
principles of the present invention is used in conjunction with flexible
baking container 171.
Carrier 201 is a rectangular plate having a central aperture 203 and is made
of metal or
temperature-resistant plastic. The shape and size of carrier 201 closely
approximate those of
the receiving channel 191 of baking container 171.
[0084] In operation, carrier 201 is received by flexible baking container 171
by
inserting the carrier 201 through the entry slot 195 of the baking container
171 and into the
receiving channel 191. The flexible properties of the baking container 171
allow the shoulder
177 to bend such that the entry slot 195 is temporarily enlarged or deformed
to accommodate
the carrier 201 as it passes through the entry slot 195 and into the receiving
channel 191.
After the carrier 201 is positioned witliin the receiving channel 191, the
shoulder 177
elastically returns to its original shape. With the shoulder 177 in a "non-
deformed" shape,
the entry slot 195 is again smaller than the receiving channel 191, which
secures carrier 201
within the receiving channel 191.
[0085] Carrier 201 provides rigidity to the flexible baking container 171 in
an area
around shoulder 177 and allows a user to more easily lift and carry the baking
container 171.
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The flexibility of the baking container 171 allows a user to easily remove the
carrier 201 from
the receiving channel 191 of the balcing container 171. The removal of the
carrier 201 could
aid a user in removing food from the baking container, although it is not
necessary to remove
the carrier 201 to effectuate the release of a food product.
[0086] Referring to FIGS. 18-21, a round, flexible baking container 211
according to
a preferred embodiment of the present invention includes a basin 212 formed by
a
substantially cylindrical, tapering wall 213 that is integrally joined at one
end to a floor 215.
A shoulder 217 is formed at an end of the wall 213 opposite floor 215, the
shoulder 217
extending completely around the perimeter of the baking container 211.
Shoulder 217
includes an outer surface 221, an inner surface 222, an upper surface 223, and
a lower surface
225. A receiving channel 231 having a circular cross section is disposed in
the shoulder 217
with an entry slot 235 positioned between the lower surface 225 of the
shoulder 217 and the
receiving channel 231. In the preferred embodiment, the entry slot 235 is
disposed adjacent
the lower surface 225 (as shown in FIG. 20), but it is conceivable that the
entry slot 235 could
be disposed adjacent the outer surface 221, the inner surface 222, or the
upper surface 223.
[0087] Referring more specifically to FIG. 21, the receiving channel 231 and
entry
slot 235 are not continuous around the entire perimeter of the flexible baking
container 211.
Instead, the receiving channel 231 includes an arcuate portion 241 that is
continuous in a
portion of the shoulder 217 and subtends an angle that is preferably greater
than or equal to
90 degrees. An exit portion 245 is of the receiving channel 231 is located at
both ends of the
arcuate portion 241. Exit portion 245 turns in a direction away from wa11213
and exits the
outer surface 221 of the shoulder 217. Because of the discontinuous nature of
the receiving
channe1231, the balcing container 211 actually contains a pair of receiving
channels 231
diametrically opposed on the shoulder 217 (see FIG. 21).
[0088] Referring to FIG. 22, a carrier 261 according to the principles of the
present
invention is used in conjunction with flexible baking container 211. Carrier
261 is formed by
a substantially rigid rod having a substantially circular cross section and
made of metal or
temperature-resistant plastic. Preferably, the material composition of the rod
is 304 stainless
steel. Carrier 261 includes a pair of central stays 265 that are joined at
each end to a handle
269. Together, the pair of central stays 265 and the pair of handles 269 form
a closed loop.
The shape and length of the central stays 265 closely approximate those of
arcuate portion
241 of the receiving channel 231. Preferably, the central stays 265 and
handles 269 are
welded together from stainless steel rods, but the carrier 261 could be formed
using any other
suitable manufacturing techniques known to those of ordinary skill in the art.
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[0089] In operation, carrier 261 is received by flexible baking container 211
by
inserting the centrals stays 265 and a portion of the handles 269 through the
entry slot 235 of
the baking container 211 and into the receiving channel 231. The flexible
properties of the
baking container 211 allow the shoulder 217 to deform such that the entry slot
235 is
temporarily enlarged to accommodate the carrier 261 as it passes through the
entry slot 235
and into the receiving channel 231. After the central stays 265 are positioned
within the
arcuate portions 241 of the receiving channels 231, the shoulder 217
elastically returns to its
original shape. With the shoulder in a "non-deformed" shape, the entry slot
235 is again
smaller than the receiving channe1231, which secures carrier 261 within the
receiving
channel 231.
[0090] With the carrier 261 installed in the receiving channel 231, a portion
of the
handle 269 is disposed within the exit portion 245 of the receiving channel,
but the majority
of the handle 269 is located outside the wall of the flexible baking container
211. Handle 269
enables a user of the flexible baking container 211 to easily lift and carry
the baking container
211 by holding either one or both handles on the portion of the handle 269
that protrudes
from the baking container.
[0091] The carrier 261 provides rigidity to the flexible baking container 211
in an
area around each shoulder 217 and allows a user to more easily lift and carry
the baking
container 211. The flexibility of the baking container 211 allows a user to
easily remove the
carrier 261 from the receiving channel 231 of the baking container 211. The
removal of the
carrier 261 could aid a user in removing food from the baking container 211,
although it is
not necessary to remove the carrier 261 to effectuate the release of a food
product.
[0092] Referring to FIGS. 23-26, a round, flexible baking container 271
according to
the principles of the present invention includes a basin 272 formed by a
substantially
cylindrical, tapering wall 273 that is integrally joined at one end to a floor
275. A shoulder
277 is formed at an end of the wall 273 opposite floor 275, the shoulder 277
extending
completely around the perimeter of the baking container 271. Shoulder 277
includes an outer
surface 281, an inner surface 282, an upper surface 283, and a lower surface
285. A
receiving channel 291 having a rectangular cross section is disposed in the
shoulder 277 with
an entry slot 295 positioned between the lower surface 285 of the shoulder 277
and the
receiving channe1291. In the preferred embodiment, the entry slot 295 is
disposed adjacent
the lower surface 285 (as shown in FIG. 26), but it is conceivable that the
entry slot 295 could
be disposed adjacent the outer surface 281, the inner surface 282, or the
upper surface 283.
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[0093] The receiving channel 291 and entry slot 295 are preferably continuous
around
the entire perimeter of the flexible baking container 271. However, it is
conceivable that a
discontinuous receiving channel 291 and entry slot 295 could be used similar
to that of
baking container 211 (see FIG. 21).
[0094] Referring more specifically to FIG. 23, a carrier 301 according to the
principles of the present invention is used in conjunction with flexible
baking container 271.
Carrier 301 is a ring-shaped plate having a central aperture 303 and is made
of metal or
temperature-resistant plastic. The shape and size of carrier 301 closely
approximate those of
the receiving channel 291 of baking container 271.
[0095] In operation, carrier 301 is received by flexible baking container 271
by
inserting the carrier 301 through the entry slot 295 of the baking container
271 and into the
receiving channe1291. The flexible properties of the baking container 271
allow the shoulder
277 to bend such that the entry slot 295 is temporarily enlarged or deformed
to accommodate
the carrier 301 as it passes through the entry slot 295 and into the receiving
channel 291.
After the carrier 301 is positioned within the receiving channel 291, the
shoulder 277
elastically returns to its original shape. With the shoulder 277 in a "non-
deformed" shape,
the entry slot 295 is again smaller than the receiving channel 291, which
secures carrier 301
within the receiving channel 291.
[0096] Carrier 301 provides rigidity to the flexible baking container 271 in
an area
around shoulder 277 and allows a user to more easily lift and carry the baking
container 271.
The flexibility of the baking container 271 allows a user to easily remove the
carrier 301 from
the receiving channel 291 of the baking container 271. The removal of the
carrier 301 could
aid a user in removing food from the baking container, althougll it is not
necessary to remove
the carrier 301 to effectuate the release of a food product.
[0097] Referring to FIG. 27, a method for baking a food product 309 according
to the
present invention includes, in step 311, providing a flexible baking container
formed from an
addition-cured silicone polymer having polytetrafluoroethylene in an amount of
about 0.1 to
15 weight percent. In step 313, a carrier adapted to be received by a
receiving channel in the
flexible baking container is provided. A user deposits a food product in the
baking container
at step 315, and the baking container is placed in an oven at a baking
temperature for a
predetermined time until the food product is baked at step 317. The baked food
product is
removed from the baking container at step 319.
[0098] Several variations of the method illustrated in FIG. 27 are possible.
First, the
use of the carrier is not required if the baking container is made from the
novel flexible
14
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balceware compound of the present invention. Alternatively, the carrier may be
used with a
traditional flexible baking container instead of one incorporating the
flexible bakeware
compound. In either situation, all of the features and advantages explained
previously in
connection with the flexible bakeware compound and carrier are applicable to
the bakeware
used with the method.
[0099] Referring to FIGS. 28-32, a bakeware apparatus 2811 according to the
principles of the present invention includes a plurality of flexible baking
containers 2813 and
a carrier 2815 adapted to carry the flexible baking containers. Carrier 2815
includes a lower
support member 2817 hingedly connected to an upper support member 2819.
[00100] Referring more specifically to FIGS. 29 and 30, the lower support
member 2817 includes a substantially planar plate 2825 with a plurality of
apertures 2827
disposed in the plate 2825. On one end of the lower support member 2817, a
plurality of
hinge members 2829 are included to allow attachment to upper support member
2819. A
hanger hole 2831 is also positioned in lower support member to allow hanging
of the lower
support member during non-use or to facilitate locking of the lower support
member to the
upper support member. The upper support member 2819 includes a substantially
planar plate
2833 having a plurality of apertures 2835 disposed in the plate 2833. A
plurality of hinge
members 2837 are positioned at one end of the plate 2833 to allow the upper
support member
2819 and the lower support member 2817 to be hingedly attached to one another.
It is
important to note that the lower and upper support members 2817, 2819 could
also be
attached by a living hinge or any other mechanism that allows the opening and
closing of the
support members 2817, 2819 relative to one another. A hanger hole 2839 is also
positioned
in plate 2833 to facilitate storage or locking of the support members 2817,
2819 in
conjunction with hanger hole 2831.
[00101] When lower support member 2817 and upper support member 2819
are hingedly attached, the support members 2817, 2819 can be moved between an
open
position (shown in FIG. 28) and a closed position (not shown). In the open
position, the
flexible baking containers 2813 can be easily removed from or placed within
the apertures
2827 of the lower support member 2817. In the closed position, the upper
support member
2819 ensures that the flexible baking containers 2813 are securely held in
place between the
support members 2817, 2819. The placement of the apertures 2827 and 2835 in
the support
members 2817, 2819 is such that when the support members 2817, 2819 are in the
closed
position, the apertures on the different support members 2817, 2819 are
concentrically
aligned with one another. It is preferred that a locking mechanism also be
included and
CA 02592805 2007-06-27
WO 2006/071993 PCT/US2005/047455
operably attached to the lower support member 2817 and the upper support
member 2819 to
allow the support members 2817, 2819 to be locked in the closed position to
prevent
accidental or inadvertent dislodgement of the flexible baking containers 2813
from the carrier
2815.
[00102] Referring more specifically to FIGS. 31 and 32, flexible baking
container 2813 preferably includes a basin 2845 having a floor 2847 surrounded
by and
integrally connected to a cylindrical wa112849. A shoulder 2851 is integrally
connected to
the wall 2849 at an end of the wall opposite floor 2847. A recessed region
2853 is provided
on the shoulder 2851, and the shoulder further includes a lower engagement
surface 2855.
The flexible baking container 2813, and more specifically the shoulder 2851,
are sized such
that when the flexible baking container 2813 is placed within the aperture
2827 of the lower
support member 2817, the lower engagement surface 2855 of the shoulder rests
upon the
plate 2825. The shoulder 2851 prevents the flexible baking container 2813 from
passing
entirely through the aperture 2827 of the lower support member 2817. The
recessed region
2853 is sized and positioned such that when the carrier 2815 is placed in the
closed position,
the plate 2833 of the upper support member 2819 preferably rests within the
recessed region
2853. An upper surface 2857 of the shoulder is not engaged by the upper
support member
2819, but rather extends tlirough the aperture 2835 on the upper support
member 2819. The
recessed region 2853 allows a more secure engagement of the flexible baking
containers
2813 when the carrier 2815 is placed in the closed position.
[00103] Referring to FIGS. 33 and 34, a bakeware apparatus 3311 according to
the
principles of the present invention includes a flexible baking container 3313,
a first carrier
member 3315, and a second carrier member 3317. The carrier members 3315, 3317
act to
provide some rigidity to the flexible baking container 3313, thereby allowing
a user to more
easily carry the flexible baking container 3313. By using more than one
carrier member, the
rigidity required to easily carry the flexible baking container 3313 is still
provided; however,
slightly more flexibility is provided by the use of two spaced-apart carrier
members 3315,
3317, which allows the user to easily twist the flexible baking container 3313
to more easily
remove food from the container.
[00104] Flexible baking container 3313 includes a basin 3325 having a floor
3327,
a pair of minor walls 3329, and a pair of major walls 3331. Both the minor
walls 3329 and
the major walls 3331 are integrally connected to the floor 3327 such that each
of the minor
walls is spaced apart and each of the major walls is spaced apart. A shoulder
3332 is
integrally connected to the minor walls 3329 and the major walls 3331 at an
end of the walls
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3329, 3331 opposite the floor. A receiving channe13333 is provided in the
shoulder 3332
similar to the receiving channel 131 in FIG. 11. The receiving channe13333 is
not
necessarily continuous throughout the entire shoulder 3332 of each of the
minor and major
walls 3329, 3331. However, the receiving channe13333 does preferably include a
central
portion 3335, a turning portion 3337, and an exit portion 3339. An entry slot
(not shown)
similar to entry slot 135 in FIG. 11 may or may not be provided. It will be
apparent to a
person having ordinary skill in the art that if an entry slot is provided the
first carrier member
3315 and the second carrier member 3317 would be easily removable from the
shoulder
3332. If an entry slot is not provided, it is more likely that the first and
second carrier
members 3315, 3317 would be co-molded with the flexible baking container 3313.
It is also
important to note that although flexible baking container 3313 includes a
shoulder 3332, the
shoulder may or may not be as pronounced as that shoulder 117 shown in FIG.
11. In fact, if
the first and second carrier members 3315, 3317 were co-molded with the
flexible baking
container 3313, a shoulder may not be included at all. Instead, the minor
walls 3329 and
major walls 3331 of the flexible baking container 3313 may be tapered as the
walls rise
upward from the floor 3327, thereby allowing the first and second carrier
members 3315,
3317 to easily fit within the walls 3329, 3331 without the need for a
shoulder.
[00105] The first carrier member 3315 and the second carrier member 3317 each
preferably include a central stay 3351, an arcuate stay 3353, and a handle
3355. When
positioned within the receiving channel 3333 the central stay 3351 is disposed
in the central
portion 3355, the arcuate stay 3353 is disposed within the turning portion
3337, and a portion
of the handle 3355 is disposed within the exit portion 3339. Another portion
of the handle
3355 is not received by the receiving channe13333, but rather extends away
from the flexible
baking container 3313 to provide an easy gripping surface for a user cariying
the bakeware
apparatus 3311.
[00106] When the first and second carrier members 3315, 3317 are installed in
the
flexible baking container 3313, a space 3359 is provided between the first and
second carrier
members 3315, 3317. Since the carrier members 3315, 3317 are not connected and
are
instead spaced apart, it is possible to twist the first carrier member 3315
relative to the second
carrier member 3317, thereby slightly twisting the flexible baking container
3313. This
twisting of the flexible baking container is very helpful because it allows a
user to more
easily remove food from the baking container. After baking a food product, the
user can
easily carry the bakeware apparatus 3311 because of the rigidity provided by
the first and
second carrier members 3315, 3317. Then the user can turn the flexible baking
container
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WO 2006/071993 PCT/US2005/047455
3313 upside down and gently twist the first carrier member 3315 relative to
the second carrier
member 3317. When the flexible balcing container 3313 experiences this slight
twisting
motion, the food product will easily drop free from the flexible baking
container 3313. The
space 3359 that exists between the carrier members 3315, 3317 may or may not
include a
receiving channe13333. Although some rigidity is lost due to the carrier
members 3315,
3317 not being connected, the overall rigidity provided by the carrier members
3315, 3317 to
the flexible baking container 3313 is enough that the carrier members 3315,
3317 still allow
for easier carrying of the flexible baking container 3313.
[00107] Referring to FIGS. 35-38, a bakeware apparatus 3511 according to the
principles of the present invention includes a flexible baking container 3513
and a carrier
3515 to be used with the flexible baking container 3513 to assist a user
carrying the flexible
baking container 3513. In the embodiment shown in FIGS. 35 and 36, the
flexible baking
container is a round baking pan having a basin 3525 formed from a floor 3527
integrally
connected to a cylindrical wa113529. The cylindrical wal13529 includes an
upper portion
3535 and a lower portion 3539. A shoulder 3543 is positioned around an upper
portion 3535
of the cylindrical wa113529 and includes a receiving channe13545 positioned
within the
shoulder 3543. The receiving channel 3545 preferably includes an arcuate
portion and an
exit portion similar to the receiving channel 231 described earlier in
reference to FIGS. 20
and 21.
[00108] Referring more specifically to FIGS. 37 and 38, it will be noted that
the
carrier 3515 is co-molded into the receiving channe13545 of the flexible
baking container
3513. In this particular embodiment, the carrier 3515 would not be removable
from the
flexible baking container 3513. However, an entry slot similar to the entry
slot 235 of FIG.
20 could be provided to allow removability of the carrier 3515 from the
flexible baking
container 3513. The carrier member 3515 includes a pair of stays and a pair of
handles
similar to the central stays 265 and handles 269 of FIG. 22.
[00109] Referring to FIGS. 39 and 40, an alternative configuration for
flexible
baking container 3513 is illustrated in which a basin 3525 includes a floor
3951 integrally
connected to a cylindrical wall 3953. Cylindrical wa113953 includes a lower
portion 3955
that tapers upward and outward to an upper portion 3957. The upper portion
3957 of
cylindrical wal13953 is preferably thicker than the lower portion 3955 in
order to eliminate
the need for a shoulder. Again, a receiving channe13965 is provided to receive
the carrier
3515. In this particular instance the receiving channe13965 is not disposed in
a shoulder, but
is rather positioned within the cylindrical wal13953 itself. The carrier 3515
is preferably co-
18
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WO 2006/071993 PCT/US2005/047455
molded to the flexible baking container 3513. However, an entry slot could be
provided to
allow removability of the carrier 3515 from the receiving channe13965.
[00110] Referring to FIGS. 41-44, a bakeware apparatus 4111 according to the
principles of the present invention includes a flexible baking container 4113
and a carrier
4115 used in conjunction with the flexible baking container 4113 to allow a
user to more
easily carry the flexible baking container 4113. The flexible baking container
4113 is
preferably a square or a rectangular baking pan and includes a basin 4125
having a floor 4127
integrally connected to a pair of minor walls 4129 and a pair of major walls
4131. The walls
4129, 4131 are configured such that each of the minor walls 4129 is spaced
apart and each of
the major walls 4131 is spaced apart.
[00111] A shoulder 4139 is disposed around the major and minor walls 4129,
4131
at an end of the walls 4129, 4131 opposite the floor 4127. The shoulder
includes a receiving
channel 4141 for receiving carrier 4115. As illustrated in FIG. 44, the
carrier 4115 may be
co-molded with the flexible baking container 4113. Alternatively, an entry
slot similar to
entry slot 135 of FIG. 11 could be included in the shoulder 4139 to allow
removal of the
carrier 4115. The receiving channe14141 preferably includes a central portion,
a turning
portion, and an exit portion similar to those described with reference to FIG.
12. Also, the
carrier 4115 preferably includes a central stay, an arcuate stay, and a handle
similar to those
described with reference to FIG. 13.
[00112] Referring to FIGS. 45 and 46, flexible baking container 4113
alternatively
may include a basin 4525 having minor walls 4527 and major walls 4529. Instead
of
including a shoulder, the minor and major walls 4527, 4529 are preferably
tapered such that
an upper portion of the walls 4527, 4529 is thicker than a lower portion of
the walls. A
receiving channel 4533 is positioned within an upper portion of the walls
4527, 4529 to
receive carrier 4115. Preferably the carrier 4115 is co-molded into the walls
4527, 4529 such
that the carrier 4115 is not removable. Alternatively, an entry slot could be
included to allow
removability of the carrier 4115 from the walls 4527, 4529.
[00113] Referring to FIGS. 47-50, a bakeware apparatus 4711 according to the
principles of the present invention includes a plurality of flexible baking
containers 4713 and
a carrier 4715 to support the flexible baking containers 4713, thereby
allowing a user to more
easily carry the flexible baking containers 4713. The flexible baking
containers 4713 are
preferably round muffin cups that can be used to bake muffins and other
cylindrically shaped
baked goods.
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[00114] The flexible baking containers 4713 each include a basin 4725 having a
floor 4727 integrally connected to a cylindrical wa114729. A shoulder 4735
surrounds the
cylindrical wall at an end of the wall 4729 opposite the floor 4727. A tab
4739 is preferably
disposed on a lower surface of the shoulder 4735 to allow the flexible baking
container 4713
to be securely fastened to the carrier 4715. Tab 4739 includes a main body
4743 and a
barbed region 4745. The main body 4743 is preferably cylindrical, and the
barbed region
4745 is greater in width (diameter) than the main body 4743.
[00115] The carrier 4715 is preferably forined from a substantially planar
plate
4759 that includes a plurality of main apertures 4761 disposed in the plate
4759. The plate
4759 is generally rectangular in shape with chamfers 4763 at the four corners
of the plate
4759. Of course, the shape of plate 4759 could be round, polygonal, or any
other shape.
Each main aperture 4761 is capable of receiving the basin 4725 of one of the
flexible baking
containers 4713. The plate 4759 has at least one attachment aperture 4765
(e.g. hole or slot)
positioned adjacent each main aperture 4761. Preferably, at least three
attachment apertures
4765 are positioned around each main aperture 4761, and the attachment
apertures 4765 are
equally spaced apart around the main apertures 4761 approximately 120 from
one another.
The attachment apertures 4765 on plate 4759 receive tabs 4739 on each flexible
baking
container 4713. Referring more specifically to FIG. 50, the barbed region 4745
of each tab
4739 is pulled through the attachment aperture 4765 such that the main body
4743 of the tab
4739 is positioned within the attachment aperture 4765 and the barbed region
4745 rests
against a lower surface of the plate 4759. The barbed region 4745 prevents the
tab 4739 from
becoming easily dislodged from the attachment aperture 4765 and serves to lock
the flexible
baking container 4713 within the main aperture 4761.
[00116] It will be apparent to a person having ordinary skill in the art that
while the
preferred embodiment includes three tabs 4739 on each flexible baking
container 4713 and
three attachment apertures 4765 positioned around each aperture 4761, a
different number of
tabs and attachment apertures could be used to secure the flexible baking
containers 4713 to
the plate 4759. It should also be apparent that while the present embodiment
is configured
such that the tabs are positioned on the flexible baking container 4713 and
the attachment
apertures are positioned on the carrier 4715, tabs could be placed on the
carrier 4715 to be
received by holes disposed in each flexible baking container 4713.
[00117] The flexible bakeware (i.e. the muffin cups 41, 51, 2813, 4713, the
rectangular baking containers 111, 171, 3313, 4113, and the round baking
containers 211,
271, 3513) composition of the present invention is preferably made from an
addition-cured
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silicone material. The following table illustrates the preferred amounts and
potential ranges
for the flexible bakeware composition of the present invention:
Compound Preferred Amount Rangeo
(Weight %) (Weight /o)
Polydimethylvinylsiloxane/Silica 60.88 40-70
High Vinyl Silicone Gum 1.1 0.5-10
Ground Quartz (filler) 28.5 5-50
Polytetrafluoroethylene 6.0 0.1-15
Black Iron Oxide (pigment) 1.1 0.1-5
Zinc Stearate (internal mold release) 0.14 0.1-5
Silicon Hydride 1.7 0.1-25
Chloro Platanic Acid (cross-linking 0.57 0.1-5
agent)
Ethynl Cyclohexanol (inhibitor) 0.01 0.05-5
[00118] The flexible bakeware compound preferably contains 0.1 to 15 weight
percent of polytetrafluoroethylene (PTFE). Testing of silicone bakeware with
these amounts
of PTFE has revealed superior release properties compared to silicone bakeware
without
PTFE. Several different compounds were tested by baking foods in the bakeware
and then
determining the amount of food residue remaining in the bakeware following the
removal of
the baked goods. Clearly, less food residue in the bakeware indicates better
release
properties. Silicone bakeware without PTFE required the use of a non-stick
spray or flour to
eliminate food residue following baking. Although silicone bakeware having
PTFE ranging
from 0.1 to 15 weight percent exhibited improved release properties without
the use of a non-
stick spray or flour, the optimum composition was determined to include six
(6) weight
percent PTFE.
[00119] The preferred particle size of PTFE used with the present invention is
approximately 6 m (i.e. microns), with a maximum particle size of 25 gm.
While larger
particle sizes of PTFE can also impart improved release properties to the
bakeware, the
plasticity of the resulting compound is sometimes increased to an extent that
extrusion and
molding of the compound is difficult or impossible. An example of PTFE
commonly used in
preparing the flexible bakeware compound of the present invention is Polymist
F-5A, which
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can be obtained from Ausimont USA. Polymist F-5A contains particles of a
relatively small
size, typically at or below 6 m.
[00120] The compounding of PTFE in the formulation of the present invention
results in the migration of PTFE to the surface of the flexible bakeware. The
presence of the
PTFE at or near the surface at least partially results in the superior release
properties of the
bakeware. Another advantage provided by the PTFE is that it does not impart an
odor or
taste to food products baked in the bakeware.
[00121] The flexible bakeware compound is preferably combined with a cross-
linking agent to insure that the bonds of the compound properly form. The
cross linking
agent may be a catalyst, such as platinum, or a curing agent such as peroxide.
A platinum
catalyst (i.e. chloro platanic acid) is preferably used in conjunction with
silicon hydride to
insure that the proper bonds form between the platinum and the silicone
compound. If a
curing agent, such as peroxide, were used, silicone hydride would not be
required. However,
peroxide is not preferred because it generally imparts an unpleasant odor and
smell to foods
baked in the bakeware. Other catalysts, including but not limited to cesium,
palladium,
rhodium, iron, cobalt, nickel, rubidium, osmium, or iridium, could be used in
place of
platinum. However, these substances are generally not favored because they are
either more
expensive (e.g. palladium) or have problems associated with contamination
(e.g. iron).
[00122] The preferred filler for the bakeware compound is ground quartz in an
amount of about 28.5 weight percent; however, filler in an amount of 5-50
weight percent
could be used. Alternative fillers include silica, calcium, or any other
mineral.
[00123] The bakeware compound preferably contains black iron oxide in an
amount of 1.1 weight percent, which gives the finished bakeware a black color.
Depending
on the desired color for the bakeware, many different pigments could be used,
and the
amount of pigment used could also be varied to alter the color. Preferably,
the weight range
of the pigment is between 0.1 and 5 weight percent.
[00124] High vinyl silicone gum is preferably added to the compound in an
amount of about 1.1 weight percent; however, the compound could include high
vinyl
silicone gum in any amount between about 0.5 and 10 weight percent. The vinyl
component
of high vinyl silicone gum is preferably 8-20 percent pendant vinyl with a
preferred amount
of 14 percent.
[00125] The novel composition of the present invention preferably has a
specific
gravity of about 1.12 to 1.64.
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[00126] Each item of flexible bakeware is preferably injection, compression,
or
transfer molded. To further enhance the release properties of the bakeware, a
molding tool
having a finish between Al and B2 is used to form the balceware, with the
preferred finish
being A2. Molding finishes of this type are known standards within the molding
industry.
[00127] It should be apparent that although the flexible bakeware of the
present
invention has been described in terms of a round muffin cup, a rectangular
baking container,
and a round baking container, any size or shape of flexible bakeware could be
included
within the scope of the present invention. Similarly, the carrier could be
provided in many
different shapes or sizes, and may include single or multiple handles that
extend outward
from the bakeware. Alternatively, the carrier may have no handles at all. The
receiving
channel shapes and sizes that are formed in each piece of flexible bakeware
could also vary
as long as the bakeware is securely attached to the carrier member and will
not become
disengaged from the carrier member while the bakeware is being transported or
carried.
[00128] It is also important to note that while the flexible bakeware has been
described as having an entry slot communicable with the receiving channel for
allowing the
carrier to be placed in the receiving channel, the entry slot could be
omitted. Without an
entry slot, the carrier would preferably be integrally molded into the
shoulder of the
bakeware. The carrier would not be removable, but the carrier would still be
carried by a
receiving channel that was formed around the carrier during the molding
process.
[00129] The primary advantage provided by the carrier is that it allows a user
of
flexible bakeware to more easily lift and transport the bakeware while baking.
By providing
rigidity around the perimeter of the flexible bakeware, it is no longer
necessary to support the
flexible bakeware from underneath such as with a cooking sheet or tray.
Another advantage
is provided by the handle portions of the carrier. The handle portions extend
outward from
the perimeter of the flexible bakeware and provide a larger gripping surface
for a user
carrying the bakeware. When the carrier is provided in a multi-piece
configuration similar to
that shown in FIGS. 33 and 34, twisting of the carriers allows easier removal
of food
products. Still another advantage of the carrier system is that it is easily
and inexpensively
manufactured. Flexible bakeware can be easily manufactured with a receiving
channel in a
shoulder that surrounds the perimeter of the bakeware. The carrier can then be
made to fit
within the receiving channel to provide the needed rigidity to a portion of
the bakeware.
[00130] The novel composition for flexible bakeware presented herein is
preferably used in conjunction with a carrier to provide the added benefits of
being able to
more easily lift and carry the balceware. However, the advantages provided by
the novel
23
CA 02592805 2007-06-27
WO 2006/071993 PCT/US2005/047455
composition are independent of those provided by the carrier. As a result of
these
independent, yet valuable, results, the novel composition may be used without
the carrier in a
manner similar to that of traditional flexible bakeware. It is also important
to note that use of
the composition described herein for flexible bakeware is not limited to use
with bakeware
having a particular size or shape.
[00131] The primary advantage provided by the bakeware composition of the
present invention is that it enables improved release of food products being
baked in the
bakeware. The composition was obtained and refined by extensive testing and
experimentation. Testing revealed that traditional flexible bakeware suffers
food release
problems unless pre-lubricated with either cooking spray, cooking oil, or
flour. The addition
of PTFE to an addition-cured silicone compound allows the manufacture of
flexible bakeware
that releases baked food without the need for pre-lubrication.
[00132] The composition described herein is not limited to flexible bakeware,
but
could be used with any product requiring the advantages presented by the
compound. In
addition to the "release" or "non-stick" advantage described previously, the
compound
provides excellent thermal insulating properties. The compound also has
exceptional stability
when exposed to cold and heat. The materials used with the compound are all
food grade
materials, so the product can be placed in contact with food. Finally, since
the compound is
silicone based, the compound provides excellent resistance to ultraviolet (UV)
light. Some of
the potential applications for the compound, outside of the flexible bakeware
application,
include but are not limited to spatulas and other cooking utensils, jello and
confectionary
molds, and ice cube trays. Other uses include cookware handles that are
essentially insulative
sleeves that slip over the hot handle of an item of cookware. The compound
could be made
into pot holders for removing hot items from an oven, or flat baking mats that
can be placed
on a cooking tray for baking cookies or other food products. Still another use
could be
sealing materials for appliance doors or windows, or any other sealing
application where a
flexible compound with good release properties is needed.
[00133] It should be apparent from the foregoing that an invention having
significant advantages has been provided. While the invention is shown in only
a few of its
forms, it is not just limited but is susceptible to various changes and
modifications without
departing from the spirit thereof.
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