Note: Descriptions are shown in the official language in which they were submitted.
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Coffee or Mocha Flavored Additive for Bakery Purposes
Field of the Invention
This invention relates to anhydrous fat-based flavoring additives primarily
intended for incorporation into baked goods. Specifically, the present
invention is
directed to discrete flavoring additive products that may be provided in the
form of
molded products, flakes, chips, chunks, or the like, which are flavored with
coffee, and
other optional additional flavors and sugar, that are carried in a bakery-
compatible fat
system which is substantially solid at room temperatures. The fat-based
flavoring
additive of the present invention has a distinctive coffee, or alternatively a
mocha flavor,
and preferably, the additive has a mouth-sense that provides a crunch or
crispness, when
consumed.
As such, a coffee or mocha-flavored molded product, flake, chip or chunk is
provided, which can be incorporated into, or on top of, bakery items such as
cookies,
cakes, muffins, biscuits, donuts, or the like. However, the additive might
also be
incorporated into or on to, ice cream products, such as ice cream sundaes, or
the like.
Typically, though, the additives of the present invention are used in the
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production of food items such as cookies, that are produced in a bakery
environment, and
that are later consumed as is, or consumed by simply removing the individual
food item
from its protective wrapping or packaging.
Background of the Invention
It has often been attempted throughout the baking industry to provide baked
goods and flour confections that may have coffee or mocha flavoring therein.
This is
usually achieved simply by the introduction of coffee, mocha, or other such
flavoring
elements directly into the other ingredients during preparation. For example,
coffee
flavouring can be added as powdered coffee, powdered instant coffee, or the
like, by
mixing the coffee product into the remaining ingredients, such as butter
and/or sugar
and/or oils. Mocha flavoring is typically achieved by adding chocolate (either
as chips,
chunks or flakes, or as chocolate mixed into the other ingredients), to a
system
comprising coffee flavoring.
However, the baking and flour confection industry and the market that it
serves
are always looking for ways to improve their products, and to introduce new
products
having specific flavors but differing presentation and/or mouth-sense. One
specific
requirement that has so far not been met has been the requirement to provide
specific
coffee or mocha-flavored additives for incorporation into, or on top of, baked
goods and
flour confections. In particular, the prior art has not provided a system
wherein the coffee
or mocha flavored additive has a discrete presence in the baked good when it
is
consumed.
In contrast, it has been known for many years to provide such discrete
flavoring
additives as chocolate chunks, peanut butter chips, butterscotch chips,
cinnamon chunks,
and the like, for baked goods and flour confections. However, heretofore, it
has not been
possible to provide such molded products, chips, chunks, or flakes for use in
bakery
products, which have a good coffee or mocha flavor release.
This is desirable since it is sometimes desired to have a product with this
flavour
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release that still has a mouth-sense, or crunch, such as that which might be
found in a
similar chocolate formulation.
Unexpectedly, the present inventor has discovered that by providing a fat-
based
carrier system that is substantially anhydrous and which comprises a bakery-
compatible
oil which preferably exhibits substantially the same or similar solid fat
index (SFI) curve
characteristics as those of cocoa butter --so that it is substantially solid
at room
temperature--then ground coffee, cocoa, or the like, and sugar may be properly
incorporated into the fat system in appropriate proportions so as to produce a
food
additive that can be used as a flavoring additive in baked goods, other flour-
based
confections, or similar products. The resultant additive product, which may
take the form
of a molded product, or a flake, chip or chunk (as those terms are used in the
baking
industry), will maintain its integrity as a discrete flavoring additive during
the baking
process, and further, when the resultant product is consumed, it will exhibit
the desired
mouth-sense whereby the molded product, flake, chip or chunk will have a
chocolate-
like crunch when it is bitten.
Prior Art
One prior flavoring additive is that taught in FEHR et al U.S. Pat. No.
3,582,353
issued Jun. 1, 1971. There, a flavored and/or colored shortening material of
hard fat
having a sharp melting point is used, and distributed into the bakery mix.
What results is
distributed localized areas throughout the baked product, when it has been
baked, that
have a particular mouth sensation similar to that of butter. The flavoring
materials may
include spices, simulated meat, fruit, fowl, or vegetable flavors, or other
dairy flavors, as
well as organic acids to provide sour flavors and the like. The resulting
baked product is
reported to have identifiable localized areas of the colored and/or flavored
flakes in spots
throughout the baked product, that have a discernable taste. It must be noted,
however,
that the FEHR et al patent describes only localized areas of concentrated
flavor where
the flavor is not necessarily a true or real flavor, and particularly which
might be
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specifically of a gummy texture and/or caramelized flavor. Moreover, the FEHR
et al
product is essentially fat, having very little solid constituent present, and
not being
capable of providing a mouth-sense which includes a chocolate-like crunch, as
in the
case of the present invention.
Further, in my earlier patent, namely US Patent No. 5447735, a flavoring
system
for providing cinnamon flavoring is provided which is similar to the present
invention.
However, mechanisms to provide coffee or mocha-flavored molded products,
flakes,
chips and chunks, are not described therein, and the use of granulated sugar
is required.
As such, a modified formulation is required.
Summary of the Invention
Accordingly, it is a principal advantage of the present invention to provide a
coffee or mocha-flavored molded product, flake, chip or chunk, for use in the
preparation
of a bakery item. This advantage, as set out hereinabove, as well as other
advantages,
objects and goals inherent thereto, are at least partially or fully provided
by the present
invention, as set out herein below.
Accordingly, in a first aspect, the present invention provides an edible,
coffee or
mocha, preferably anhydrous, fat-based flavored food additive in the form of a
molded
product, flake, chip of chunk; wherein said flavored food additive is intended
for
incorporation into baked goods or for use in snack items, and comprises from
substantially 0% to 5% by weight, and more preferably from 0.1 to 2%, of
moisture,
from about 2% to about 35% by weight of a finely ground natural flavoring
agent
comprising coffee and optionally cocoa, from about 25% to about 35% by weight
of a
bakery-compatible oil that is substantially liquid at about 35 degrees C. to
about 40
degrees C., with the balance being sugar.
Preferably, the bakery-compatible oil is a fat or oil that exhibits a solid
fat index
(SFI) curve characteristic having defined ranges of solid fat and liquid fat
components at
defined temperatures. One suitable example would be as follows:
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10.0 degrees C.--43-66% solid fats, balance liquid fats
21.1 degrees C.--32-52% solid fats, balance liquid fats
26.6 degrees C.--20-44% solid fats, balance liquid fats
33.3 degrees C.--6-25% solid fats, balance liquid fats, and
40.0 degrees C.--0-5% solid fats, balance liquid fats.
Also, the bakery-compatible oil is preferably selected from the group
consisting
of vegetable oils, cocoa butter, and liquid butter fats, and mixtures thereof,
which
preferably exhibit the said solid fat index curve characteristic.
Still further, the bakery-compatible oil is preferably one that solidifies at
temperatures of about 6 degrees C. to about 12 degrees C. and remains
substantially
solidified at temperatures below about 35 degrees C.
Detailed Description of the Invention
It will be understood, for purposes of this discussion, that use of the words
"flakes", "chips", "chunk" or the like, are to be interpreted in the manner
that those terms
are used in the bakery industry. For example, "flakes" implies that the
manufactured
fat-based discrete flavoring additive product has a relatively small thickness
compared to
its length or breadth. A "chunk" is typically interpreted as having a
relatively large
thickness compared to its length and breadth. In general, neither flakes or
chunks are
molded; rather, they are typically manufactured from a semi-liquified layer of
mixed
ingredients that will flow, and which are placed on a moving belt and passed
through a
cooling tunnel to solidify. The solidified material can then be broken into
flakes or
chunks.
A chip product may also be produced methods known to those skilled in the art,
such as by extrusion of a semi-liquified material into a desired, typically,
tear-dropped
shape.
Still further, the flavored food additive may be molded to a specific shape or
size,
by solidification of product within a suitably shaped mold. One particularly
desired
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shape of the food additive of the present invention is to provide a product
that has been
molded into the shape of a coffee bean. The size of the "coffee bean" can be
adjusted to
be suitable for its intended application. Thus, a coffee bean shaped product,
as well as
the flakes, chips, and chunks of the discrete food additive, can be any
suitable size for
incorporation into the bakery product.
Preferably though, the flavored food additive of the present invention, has a
size
between 3 to 30 mm, and more preferably, between 5 and 15 mm.
The food additive is preferred used so that it is incorporated into, or on top
of,
bakery items such as cookies, cakes, muffins, biscuits, donuts, or the like.
Other bakery
items, can include items such as tea biscuits, arrowroot, bran filled
digestive biscuits,
graham wafers, and the like. Further, the additive might also be incorporated
into or on
to, non-bakery food items, such as for example, ice cream products, including
ice cream,
ice cream sundaes, ice cream cones, or the like. As such, the flavored
additive of the
present invention can be used in the production of a wide variety of different
foods.
The skilled artisan will, however, also be aware that the food additive of the
present invention might be consumed as is, or optionally provided in slightly
larger
format for use as a snack item. For these snack item applications, the size of
the flavored
food additive be increased to between 10 and 40 mm. However, this is not the
primary
intended use of the flavored additive of the present invention.
A most important goal of the present invention, however, is to provide a
discrete
flavored, food additive, so that coffee (or mocha, or other additional natural
flavoring
ingredients), may be carried into a baked product while being suspended in a
bakery-compatible fat which provides the desired mouth-sense and feel.
In keeping with the present invention, the fat-based, discrete flavoring
additive,
or the snack item, is preferably substantially anhydrous, in that it is has
from
substantially 0% to about 5%, and more preferably from 0.1% to 2 %, by weight
of
moisture therein.
The discrete flavoring flake, chip or chunk, or molded product, that is made
in
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keeping with the present invention will have from about 2% to about 35% by
weight of
finely ground coffee and optionally cocoa, together with from about 25% to
about 35%
by weight of a bakery-compatible oil, with the balance being sugar.
The coffee level is preferably between 2 and 20% by weight of the total
formulation, and more preferably, between 3 and 12%. The coffee is preferably
a
naturally occurring coffee bean or powder that has been finely ground, in
keeping with
well known procedures therefor.
Cocoa is preferably added as a optional coloring agent and/or as a flavoring
agent. The preferred level of cocoa is between 0 and 18%, and more preferably,
between
5 and 15%, by weight. A naturally occurring, finely ground, powdered cocoa
material
which is produced in keeping with known procedures therefor, is preferred.
In general, at lower levels, the cocoa primarily acts as a coloring agent to
provide
a dark, richer looking discrete additive. At higher levels, the flavor of the
cocoa is more
pronounced, and the combined coffee and cocoa flavoring produces a "mocha"
flavoring.
At still higher levels, the cocoa flavor can begin to mask the coffee flavor.
Any suitable type of coffee or cocoa might be used, depending on taste
considerations, pricing, and availability.
Likewise, other natural flavoring ingredients that are compatible with the
system
of the present invention might also be added. Specifically, the present
invention
contemplates that other natural flavoring agents would also be preferably
finely ground
so as to be suspended in the fat system, together with the coffee, cocoa or
sugar. These
additional flavoring ingredients can include materials such as, for example,
ginger,
nutmeg, cloves, allspice, maple sugar (or dehydrated maple syrup), or mixtures
thereof.
As to the sugar component, it is a preferably a finely ground sugar. Thus,
confectioner's sugar or powdered sugar is preferred in order to produce a
flavored
additive of the present invention, which has a good mouth-sense, and which is
not coarse
or un-refined.
Optionally, granulated sugar can be added in the final stages of production,
to
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provide modifications to the look and mouth-sense of the final product.
Typically, the
level of granulated sugar is less than 25% of the total added sugar, and more
preferably,
less than 10% of the total added sugar.
The fat (or oil) component is preferably a homogenous mixture of oils in any
desired proportion of vegetable oils, cocoa butter, and liquid butter fats
ranging from
substantially 0% to substantially 100%, and mixtures thereof. It is to be
noted that the
finely ground coffee, cocoa or other optional flavoring ingredients, as well
as the fine
sugar components, are preferably added to the fat system so that the powdered
products
are held in suspension in the fat system. As such, when the fat component is
liquid, then
the coffee, cocoa and/or sugar are held in suspension; and when the fat system
solidifies,
the coffee and cocoa are still held in suspension but in much more immobile
fashion
since at lower temperatures there is substantially little liquid fat
component.
The bakery-compatible oil is such that it is preferably substantially liquid
at
elevated temperatures of about 35degrees C. to about 40 degrees C. Preferably,
the
bakery-compatible oil may be a suitable vegetable oil, cocoa butter, liquid
butter fat, or
other liquid dairy fat, and mixtures thereof, which are liquid or liquefiable,
during the
manufacturing stage. In any event, the bakery-compatible oil will exhibit
generally
similar solid fat index and melting points as those of cocoa butter, as
described in greater
detail hereafter. Moreover, the bakery-compatible oil must be such that it may
be
miscible with liquid cocoa butter at temperatures of about 35 degrees C. to
about 50
degrees C., so that if they are mixed they will make a substantially
homogenous mixture.
Moreover, any bakery-compatible oil or mixtures thereof with liquid dairy fat
will
preferably be such that it will crystallize in much the same manner as
chocolate when
found in chocolate-compatible fats, so that when solid the product will offer
a snap in
much the same way that chocolate will snap if it is broken. As such, the food
additive of
the present invention, will preferably have a chocolate-like texture when
consumed.
Moreover, as noted above, the characteristic SFI curves which describe the
solid
fat index and melting points of the bakery-compatible oils, cocoa butter,
and/or butter
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fat, should be substantially similar to each other, and thus they will exhibit
the
characteristic that they are sufficiently stable at about room temperature of
about 20
degrees C. so that the oils will not smear during mixing with other prescribed
ingredients of the baked or other goods being made, prior to those goods being
baked or
otherwise prepared.
Additionally, however, the bakery-compatible fats or oils used should remain
substantially solidified and relatively firm during the baking process.
Further, though, the
bakery-compatible oils used in the fat system of the present invention are
preferably such
that they will commence to melt in the mouth at approximately 35 degree C.;
and of
course, the oils or fats used in the fat system of the present invention must
not otherwise
conflict with, or be intolerable with the intended baked goods, flour
confections, snack
items, or other food products into which they will be incorporated.
Of course, it is also true that the oils or fats and other ingredients used in
preparation of the discrete flavoring additives, or snack items, of the
present invention
must be compatible with requirements for controlled ingredient regulations,
legends and
other labeling provisions that are imposed on food products. Preferably, the
oils or fats
used herein, therefore, are vegetable-based oils and fats, and preferably are
oils or fats
which are free of trans fats. Suitable oils can include cocoa butter,
fractionated palm
kernel oil, or the like, but other oils will be known to the skilled artisan.
The preferred bakery-compatible oils used in the present invention are
preferably
miscible with liquid cocoa butter in any proportion, at temperatures of about
35 degrees
C. to about 50 degrees C. Thus, if they are mixed together, they will make a
substantially
homogenous mixture. If so, then they will solidify or crystallize at lower
temperatures as
an homogenous mixture. The following table provides a typical solid fat index
(SFI)
curve range for suitable vegetable oils, liquid butter fats, and mixtures
thereof, which
characteristics are essentially those of cocoa butter or butter fat, and which
in any event
can be generally described, as follows:
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TYPICAL SOLID FAT INDEX (SFI) CURVE
10.0 degrees C. 43-66% solid fats, balance liquid fats
21.1 degrees C. 32-52% solid fats, balance liquid fats
26.6 degrees C. 20-44% solid fats, balance liquid fats
33.3 degrees C. 6-25% solid fats, balance liquid fats
40.0 degrees C. 0-5% solid fats, balance liquid fats
It may be that, in order to achieve the solid fat index curve characteristics
set
forth in the table above, it will be necessary to process the solid fats of
the vegetable oils
being used by blending or processing them, but only to the extent necessary so
as to
obtain the solid fat index curve having the defined ranges of solid and liquid
components
at the defined temperatures. Moreover, so as to generally exhibit a snap when
broken, the
solidified fats will usually be more to the solid limits within the above
table. Thus,
so-called "hard butter" -- vegetable oils and mixtures thereof showing butter
fat solid fat
index curve characteristics at the more solid end of the ranges of the above
table- or the
like, are particularly useful for purposes of the present invention.
From the above, it is clear that the oils and/or liquid fats being used are
preferably substantially in a liquid phase above about 35 degrees C. to about
40 degrees
C., and are miscible as liquids, and that they are substantially solidified at
least at about 6
degrees C. to about 12 degrees C. Moreover, once solidified, they will remain
firm and
will show no tendency to smear at about room temperature of 20 degrees C.
As such, it is preferred that the additive, and more particularly, the
bakery-compatible oil exhibits the characteristic that it is stable at about
room
temperature so as not to smear during mixing with the other prescribed
ingredients of the
baked goods into which said discrete flavoring additive is being incorporated,
prior to
baking the baked goods.
The bakery-compatible oil, when liquid, might be mixed with liquid butter fat.
Regardless, though, the bakery-compatible oil will preferably exhibit
substantially
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identical solid fat index curve characteristics as those of cocoa butter or
butter fat. What
that means is that the fat ingredients of the present invention will exhibit
solid, melting,
and liquid characteristics similar to those of cocoa butter or butter fat
whether or not
cocoa butter or butter fat is, indeed, included in the homogenous mix of
bakery-compatible oils. Therefore, certain dietary and/or religious
requirements which
preclude the actual use of butter, for example, in certain food items which
may be
consumed at particular times, can be fully satisfied by the fat-based
flavoring products,
flakes, chips or chunks of the present invention.
Because of the fat system incorporated into fat-based discrete flavoring
additives
of the present invention, the flakes, chips, chunks or molded products,
provided by this
invention may be incorporated into baked products, in such a manner that
products such
as tea biscuits, cookies or muffins which may have a relatively fast baking
time--for
example, ten or fifteen minutes--at baking temperatures of about 177 degrees
C. may be
made; while other discrete flakes, chips, chunks or molded products, according
to the
present invention may be baked into breads or other confections that might
have baking
times of thirty to forty minutes at temperatures above 177 degrees C.
Preferably, therefore, the bakery-compatible oil exhibits the characteristic
that it
has slow flow rates so as to stay substantially firm during a baking process
at
temperatures of from about 170 degrees C. up to about 200 degrees C., for
periods of
from about 5 minutes up to about 45 minutes.
The skilled artisan will also be aware, though, that when used in colder
applications, such as ice cream formulations, the types of oils and fats can
be adjusted so
as to provide a fat component having an SFI curve characteristics more
suitable for lower
temperature applications. One suitable SFI curve for lower temperature
applications
would be as follows:
10 C 40 + 5% solid fats, balance liquid fats
23.10 C 15 5% solid fats, balance liquid fats
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28.9 C 9 f 3% solid fats, balance liquid fats
32.3 C 3 1% solid fats, balance liquid fats
40 C 0% solid fats, balance liquid fats .
However, the skilled artisan would be aware that other SFI curves could also
be
suitable.
Optionally, the flavored flakes, chips, chunks or molded products of the
present
invention, can additionally comprise a dairy component. As such, the chips,
chunks,
flakes or molded products can comprise milk or cream solids in the amount of
about 0 to
15%, by weight of the total additive formula, more preferably between 3 to
12%, and
most preferably, between 4 to 10%, by total formula weight. The milk or cream
solids
are preferably added as powdered milk or cream. If the optional dairy
component is also
added, however, the amount of cocoa is preferably reduced to a range of from 1
to 10%,
by weight of the formulation, or more preferably, to a range of from 2 to 8%,
by total
additive formula weight.
The level of milk or cream solids added can also be adjusted to provide a
desired
flavoring effect, such as for example, providing a milk and coffee flavoring,
or a coffee
and cream combination. This taste can be adjusted to suit any particular
preference by
the user.
As for the snack food item possibility, the snack food item provided by the
present invention would employ essentially the same fat system as that
described
hereinabove, which is flavored with coffee, sugar, optionally cocoa (for
coloring, or to
obtain a mocha flavoring), optionally milk or cream solids, and other
additional
flavorings, in accordance with the flavored food additive formulations
provided
hereinabove.
Turning now to the process by which the anhydrous fat-based discrete flavoring
additives of the present invention are manufactured, the process preferably
utilizes
techniques already known within the art. One possible production method is
similar to
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the production process used in the production of the cinnamon-flavored food
additive
which is described in US 6368655. As such, one example of a suitable
production
process would typically comprise the following steps, namely:
(a) mixing the bakery-compatible oil with finely ground coffee and optionally
cocoa in a mixer at a temperature of about 35 degrees C. to about 50 degrees
C., so as to
obtain an homogenous mixture having the coffee (and cocoa) suspended therein;
(b) transferring the homogenous mixture to a holding tank, and maintaining the
temperature of the homogenous mixture at about 39 degrees C. to about 45
degrees C.;
(c) continuously agitating the homogenous mixture while it is in the holding
tank;
(d) pumping the homogenous mixture to a tempering unit, continuously agitating
the homogenous mixture while in the tempering unit, and slightly cooling the
homogenous mixture to about 29 degrees C. to about 34 degrees C.;
(e) transferring the slightly cooled homogenous mixture to a further mixing
tank,
and mixing sugar therewith;
(f) transferring the resultant sugar, coffee, oil and optionally cocoa mixture
to a
further discrete particle manufacturing means so as to produce discrete
flakes, chips,
chunks or molded products, from that resultant mixture;
(g) cooling the discrete flakes, chips, chunks or molded products to a
temperature
of from about 6 degrees C. to about 12 degrees C.; and
(h) finally, removing the cooled discrete flakes, chips, chunks or molded
products
for further handling and/or storage and/or shipping.
The resultant flakes, chips, chunks or molded products, are ready to be
incorporated into, or on to, a variety of goods, but most notably into or on
to, baked
products such as cookies, cakes, muffins, or the like, as previously
mentioned.
Additional details of the food additive production technique, however, are
outside of the scope of this invention, and will not be described in any
further detail.
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There has therefore been described an anhydrous fat-based discrete flavoring
additive in which coffee, optionally cocoa, fats or oil, and sugar are
provided as discrete
flakes, chips or chunks for incorporation into baked goods, flour confections,
ice cream
products, or the like. The discrete flavoring additive is such that it will
retain its integrity
as a flake, chip, chunk or molded product, even when it is incorporated into
baked goods,
and will provide a chocolate-like mouth-sense, together with a distinct coffee
(or mocha
or cocoa) flavor. As noted, other flavoring ingredients that are compatible
with the
system of the present invention, might also be included.
Further, there has also been described a snack item which can be consumed as
is,
which gives a pleasant chocolate-like mouth sensation, together with a
distinct coffee (or
mocha or cocoa) flavor.
Accordingly, it is apparent that there has been provided, in accordance with
the
present invention, a discrete coffee or mocha-flavored food additive, such as,
or flake,
chip, chunk, or a molded product, which fully satisfies the goals, objects,
and advantages
set forth hereinbefore. Therefore, having described specific embodiments of
the present
invention, it will be understood that alternatives, modifications and
variations thereof
may be suggested to those skilled in the art, and that it is intended that the
present
specification embrace all such alternatives, modifications and variations as
fall within
the scope of the appended claims.
Additionally, for clarity and unless otherwise stated, the word "comprise" and
variations of the word such as "comprising" and "comprises", when used in the
description and claims of the present specification, is not intended to
exclude other
additives, components, integers or steps. Further, the invention
illustratively disclosed
herein suitably may be practiced in the absence of any element which is not
specifically
disclosed herein. Moreover, unless otherwise specifically noted, all of the
features
described herein may be combined with any of the above aspects, in any
combination.
Further, the words "substantially" or "essentially", when used with an
adjective
or adverb is intended to enhance the scope of the particular characteristic;
e.g.,
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substantially planar is intended to mean planar, nearly planar and/or
exhibiting
characteristics associated with a planar element.
Further, use of the terms "he", "him", or "his", is not intended to be
specifically
directed to persons of the masculine gender, and could easily be read as
"she", "her", or
"hers", respectively.
Also, while this discussion has addressed prior art known to the inventor, it
is not
an admission that all art discussed is citable against the present
application.
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