Note: Descriptions are shown in the official language in which they were submitted.
CA 02730815 2011-02-04
Attorney Docket No. 6618CA01
LAYER CUTTING APPARATUS
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. Patent Application Serial
No.
11/334,809 filed on January 18, 2006 which claims benefit of U.S. Provisional
Patent
Application Serial No. 60/655,211, filed February 22, 2005, entitled "LAYER
CUTTING APPARATUS", which are incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates generally to layer cutting assemblies. More
particularly,
the invention relates to a layer cutting tray and sleeve apparatus for
allowing a user to
slice layers of baked goods accurately and evenly.
BACKGROUND
During the commercial preparation of food products, especially products for
the bakery or foodservice industries, it is often desirable to cut a cake or
other product
into some predetermined form or shape. For example, in the case of frozen
cakes, it is
common for a commercial kitchen or bakery to employ hand laborers to slice the
cakes into layers for further decorating or sale.
In many kitchens, a large knife is used to separate frozen cakes into layers.
This technique is labor intensive and often requires extreme care to avoid
injuries to
kitchen personnel. Forming layers with a knife also requires a certain level
of skill to
ensure the layers are visually appealing.
In view of the, considerations outlined above, a variety of cutting assemblies
have been developed to separate cakes into layers. Known prior art includes
U.S.
Patent No. 2,589,911; U.S. Patent No. 3,277,754; U.S. Patent No. 4,213,241;
U.S.
Patent No. 2,964,844; U.S. Patent No. 817,027; and U.S. Patent No. Des.
363,870.
While these devices fulfill their particular objectives and requirements, the
aforementioned devices are large and cumbersome. Accordingly, they tend to
consume significant space in commercial facilities. Therefore, known layer-
cutters are
not always adaptable to existing layouts.
SUMMARY
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A primary object of the invention is to provide a layer cutter that is safe,
effective and efficient in the setting of a home kitchen, or commercial
foodservice
operation, such as an institutional kitchen or bakery.
Another object of the invention is to provide a layer cutting device that is
capable of smooth and quiet operation that does not require a source of
electric power.
It is another object of the invention to provide a layer cutting apparatus
that is
capable of cutting layers into food products that are firm enough to maintain
a distinct
shape.
It is yet another object of the invention to provide a layer cutting apparatus
that is incorporated into the packaging of high volume cakes and capable of
one-time
use.
These and other objects of the invention are achieved by providing a layer
cutting apparatus including a tray having an interior defined by a bottom and
sidewall.
A sleeve is at least partially disposed in the interior of the tray, and a
cutting line is
attached to the sleeve. The cutting line is configured to be removed from the
sleeve by
pulling the line outward from one point of the sidewall.
In another aspect of the invention, the invention includes a method of
dividing
a food product into layers. The method comprises providing a tray containing a
food
product. The tray has a bottom, a first side, a second side, a front wall, and
a back
wall. The method also includes the steps of suspending a line between the
first side
and the second side, adjacent to the front wall and moving the line along the
first side
and the second side from a position adjacent to the front wall to a position
adjacent to
the back wall.
In yet another embodiment, the invention includes a food package kit
comprising a tray having a bottom. A food product is disposed on the bottom of
the
tray. A sleeve is at least partially disposed about the perimeter of the food
product. A
cutting line is attached to the sleeve. At least a portion of the cutting line
is located
between the sleeve and the food product.
These and other aspects of the invention will be more apparent from the
following description of the preferred embodiment thereof when considered in
connection with the accompanying drawings and appended claims.
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DESCRIPTION OF THE DRAWINGS
The invention may be more completely understood in consideration of the
following detailed description of various embodiments of the invention in
connection
with the accompanying drawings, in which:
FIG. 1 shows an isometric view of a layer cutting apparatus pursuant to the
invention.
FIG. 2 shows an isometric view of a cutting sleeve pursuant to the invention.
FIG. 3 shows an isometric view of a cutting tray pursuant to the invention.
FIG. 4 shows an isometric view of a cake that has been separated into layers
using the invention.
FIG. 5 shows a top plan view of a layer cutting apparatus pursuant to the
invention.
FIG. 6 shows a top plan view of the layer cutting apparatus during the cutting
process.
FIG. 7 shows a top plan view of the layer cutting apparatus during the cutting
process.
FIG. 8 shows a top plan view of the layer cutting apparatus during the cutting
process.
FIG. 9 shows a top plan view of the layer cutting apparatus during the cutting
process.
FIG. 10 shows a top plan view of the layer cutting apparatus during the
cutting process.
FIG. 11 shows a top plan view of the layer cutting apparatus during the
cutting process.
FIG. 12 shows a top plan view of an alternative embodiment of the layer
cutting apparatus during the cutting process.
FIG. 13 shows a top plan view of an alternative embodiment of the layer
cutting apparatus during the cutting process.
FIG. 14 shows a top plan view of an alternative embodiment of the layer
cutting apparatus during the cutting process.
FIG. 15 shows a top plan view of an alternative embodiment of the layer
cutting apparatus during the cutting process.
FIG. 16 shows a top plan view of an alternative embodiment of the layer
cutting apparatus during the cutting process.
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FIG. 17 shows an isometric view of an alternative embodiment of the layer
cutting apparatus.
FIG. 18 shows an isometric view of another alternative embodiment of the
layer cutting apparatus.
FIG. 19 shows an isometric view of yet another alternative embodiment of the
layer cutting apparatus.
FIG. 20 shows an isometric view of a multiple layer cutting apparatus.
FIG. 21 shows a top view of an alternative embodiment of the layer cutting
apparatus during an initial stage' of the cutting operation.
FIG. 22 shows a top view of an alternative embodiment of the layer cutting
apparatus during a final stage of the cutting operation.
FIG. 23 shows an isometric view of an alternative embodiment of the cutting
apparatus incorporating a sleeveless cutting configuration.
FIG. 24 shows an isometric view of an alternative embodiment of the cutting
apparatus incorporating a portion forming mechanism.
FIG. 25 shows an exploded isometric view of another alternative embodiment
of the layer cutting apparatus.
FIG. 26 shows an exploded isometric view of another alternative embodiment
of the layer cutting apparatus.
FIG. 27 shows an isometric view of the layer cutting apparatus of FIG. 26.
FIGS. 28-31 show top plan view of the layer cutting apparatus of FIGS. 25-27
during the cutting process.
While the invention is amenable to various modifications and alternative
forms, specifics thereof have been shown by way of example in the drawings and
will
be described in detail. It should be understood, however, that the intention
is not to
limit the invention to the particular embodiments described. On the contrary,
the
intention is to cover all modifications, equivalents, and alternatives falling
within the
spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1 through 3, the cake-layer cutting apparatus 10
embodying the principles and concepts of the present invention will be
described.
Apparatus 10 includes sleeve 12 and tray 14. Sleeve 12 is configured to fit
inside the
inner periphery of tray 14 as shown.
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Sleeve 12 includes an elongated first side 16 terminating at a first corner 18
and a second corner 20. A second side 22 extends from first side 16 at first
corner 18.
Second side 22 terminates at third comer 32. Similarly, a third side 24
extends from
first side 16 at second corner 20. Third side 24 terminates at fourth comer
30. Panel
26 extends from third side 24 at fourth corner 30. Panel 28 extends from
second side
22 at third corner 32. Aperture 34 defines the area between panel 26 and panel
28.
Sleeve 12 includes a top edge 36 and a bottom edge 38. In FIG. 2, top edge 36
is shown parallel to bottom edge 38 although this configuration is not
necessary to the
invention. Cutting line 40 is shown extending through aperture 34. Cutting
line 40 is
attached to sleeve 12 in a plurality of locations throughout first side 16,
second side
22, third side 24, panel 26, and panel 28. In one embodiment, cutting line 40
is woven
through sleeve 12 in a linear fashion. In an alternative embodiment, cutting
line 40
may be attached to sleeve 12 using adhesive. In yet another embodiment,
cutting line
40 may be disposed within sleeve 12.
The portion of cutting line 40 woven through first side 16 forms a first
segment 42. The portion of cutting line 40 woven through second side 22 forms
a
second segment 44. The portion of cutting line 40 woven through third side 24
forms
a third segment 46. The portion of cutting line 40 woven through panel 26
forms a
beginning segment 48. The portion of cutting line 40 woven through panel 28
forms
an end segment 50. Segments 42, 44, 46, 48, and 50 are generally parallel to
bottom
edge 38. In an alternative embodiment, segments 42, 44, 46, 48, and 50 could
comprise a wavy or zig-zag configuration as shown in FIG. 19. For example,
when
cutting line 40 is pulled away from first side 16 of sleeve 12, a wavy pattern
is
created. As cutting line 40 is pulled away from second side 22 of sleeve 12, a
jagged
zig-zag, pattern is created.
In one embodiment, sleeve 12 is fabricated of corrugated or paperboard. In
another embodiment, sleeve 12 is fabricated of another paper-based product in
the
range of about 20-52 lb. per ream weight. Sleeve 12 may be fabricated of a
variety of
other food approved materials of sufficient rigidity to withstand the force of
cutting
line 40 as it is removed from sleeve 12. In a preferred embodiment, materials
for
sleeve 12 are capable of maintaining their structural integrity during baking
temperatures exceeding 350 F (177 C). Alternative materials for sleeve 12
include
various metals, glass, or thermoformed plastic material, such as polyolefins
(e.g.,
polypropylene, polyethylene), blends of polyolefins, polystyrene - HIPS, or
polyester
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resin-based materials - CPET, foamed polypropylene, polyethylene), blends of
polyolefm's polystyrene - HIPS, or polyester resin-based materials - CPET,
paper and
paper laminations with polypropylene, polyester, etc.
With reference to FIG. 3, tray 14 will now be discussed. Tray 14 includes a
bottom 100 and sidewall 102. Sidewall 102 extends upward from the perimeter of
the
bottom 100. Bottom 100 is shown in a rectangular configuration, although
bottom 100
can be comprised of any 2-D shape, regular or irregular, including circles,
triangles,
footballs, hearts, or any other polygon while remaining within the scope of
the
invention.
Sidewall 102 includes an elongated first wall 104 terminating at first corner
112 and second corner 114. Second wall 106 extends from first wall 104 at
first
corner 112. Second wall 106 terminates at third corner 116. Third wall 110
extends
from first wall at second corner 114. Third wall 110 terminates at fourth
corner 118.
Fourth wall 108 is disposed between third corner 116 and fourth corner 118.
Notch
120 is disposed in fourth wall 108 such that notch 120 extends below top
surface 122
of fourth wall 108. Notch 120 provides clearance for cutting line 40 when
sleeve 12
rests on bottom 100 of tray 14 as shown in FIG. 1. Notch 120 may comprise a
variety
of configurations, including a hole or an "L" shaped cutout as shown in FIGS.
20 and
24, while remaining within the scope of the invention. Alternatively, notch
120 may
be located at any one of corners 112, 114, 116, or 118 while remaining within
the
scope of the invention. Additionally, notch 120 may be at any location along
any of
the walls.
Top surface 122 extends around notch 120 at fourth wall 108, second wall
106, first wall 104, and third wall 110. In one embodiment, top surface 122
defines a
plane substantially parallel to the plane that includes bottom 100, although
such
configuration is not necessary to the invention.
Tray 14 is preferably fabricated of paperboard or a similar paper product.
However, tray 14 may be fabricated of a variety of other food approved
materials of
sufficient rigidity to at least partially support the weight of a food
product. In a
preferred embodiment, materials for tray 14 are capable of maintaining their
structural
integrity during baking temperatures exceeding 350 F (177 C). Alternative
materials
for tray 14 include various metals, glass, or thermoformed plastic material of
the type
previously described.
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1 '
Tray 14 may be a variety of sizes sufficient to contain a food product 200
while remaining within the scope of the invention. In one embodiment, the
distance
between first wall 104 and fourth wall 108 is between about 3 inches and about
30
inches. In another embodiment, the distance between first wall 104 and fourth
wall
108 is about 16.75 inches. The distance between second wall 106 and third wall
110 is
between about 3 inches and about 35 inches. In another embodiment, the
distance
between second wall 106 and third wall 110 is about 24.75 inches. Similarly,
the
height of sidewall 102 from bottom 100 to top surface 122 may also comprise a
variety of sizes while remaining within the scope of the invention. In one
embodiment, the height of sidewall 102 is between about 1 inch and about 8
inches.
In operation, a food product can be baked in the interior of tray 14.
Alternatively, a pre-made food product can be placed on the bottom 100 of tray
14.
The food product can be a cake, intermediary food product, or any other baked
good.
Next, sleeve 12 is placed in tray 14 so that at least a portion of the sleeve
12 is
between the food product and the second sidewall 106. In a preferred
embodiment,
sleeve 12 rests on the bottom 100 of tray 14 and extends around the perimeter
of the
food product, between the food product and the sidewall 102.
FIG. 4 shows a food product 200 that has been sliced using apparatus 10. Food
product 200 is divided into an upper layer 202 and a lower layer 204 at
partition 206.
The plane that defines partition 206 is substantially parallel to the plane
that defines
bottom 100. This aspect of the invention enables lower layer 204 to maintain a
uniform thickness from first end 208 to second end 210. A layer of non-stick
parchment paper may be located between lower layer 204 and bottom 100.
Alternatively, bottom 100 may be treated with a releasing compound or non-
stick
substance.
In one embodiment, cutting line 40 includes a cotton string. In alternative
embodiments, cutting line 40 includes a metal wire, nylon monofilament,
polymer-
based string, elastomer filament or similar filament capable of withstanding
baking
temperatures. Cutting line 40 can be fabricated of a variety of other
materials having
sufficient tensile strength to withstand the force required to separate
cutting line 40
from sleeve 12 and move cutting line 40 through a food product 200 during the
cutting process. Suitable materials have a tensile strength of at least 1
pound per
square inch. Common diameters of cutting line 40 are in the range of about 1
mm to
about 0.25 inches.
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With reference to FIGS. 5-11, the cutting operation of apparatus 10 will now
be discussed. FIG. 5 illustrates the location of the food product 200 inside
tray 14.
Sleeve 12 is disposed about the perimeter of food product 200 such that
aperture 34 is
adjacent to notch 120. Cutting line 40 extends through aperture 34 and notch
120 and
is attached to sleeve 12 throughout panel 26, third side 24, first side 16,
second side
22, and panel 28.
During the cutting operation, cutting line 40 is pulled outward from notch
120.
As the force on cutting line 40 overcomes the force attaching cutting line 40
to panel
26, cutting line 40 is pulled away from panel 26 and fourth corner 30 as shown
in
FIG. 6. The portion of cutting line 40 disposed inside food product 200 begins
cutting
food product 200 into layers.
As shown in FIG. 7, cutting line 40 is pulled outward from notch 120 to
continue cutting the food product 200 into layers. Cutting line 40 continues
to pull
away from third side 24 until cutting line 40 is pulled away from second
corner 20 as
shown in FIG. 8. Next, a user continues pulling cutting line 40 outward from
notch
120 so that cutting line 40 is pulled away from first side 16 and first corner
18 as
shown in FIGS. 9 and 10. At this point, more than 75% of the food product 200
has
been divided into layers.
As cutting line 40 continues to be pulled outward from notch 120, cutting line
40 is pulled away from second side 22 as shown in FIG. 11. Once line is pulled
past
third corner 32, the food product 200 is completely divided into layers.
An alternative embodiment of the cutting process is shown in FIGS. 21 and
22. In this embodiment, cutting line 40 is pulled outward from notch 120 at
both ends.
This enables cutting line 40 to simultaneously separate from sleeve 12 along
second
side 22 and third side 24. Once cutting line 40 is pulled away from first
corner 18 and
second corner 20, cutting line 40 separates from first side 16 as shown in
FIG. 22.
Once cutting line 40 completely separates from first side 16, cutting line 40
may be
pulled entirely through notch 120.
In yet an alternative embodiment, cutting line 40 may be attached directly to
the sidewall 102 of tray 14 as shown in FIG. 23. Sidewall 102 includes first
wall 104,
second wall 106, third wall 110, and fourth wall 108. As cutting line 40 is
pulled
away from notch 120, cutting line 40 separates from sidewall as previously
discussed.
FIG. 12 illustrates an alternative embodiment of the apparatus 10. In this
embodiment, sleeve 12 contains three sides including a first side 16, a second
side 22,
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and a third side 24. Sides 16, 22, and 24 are located around three sides of
food product
200, between food product 200 and the sidewall 102. Notch 120 is located
adjacent to
corner 180 of tray 14. Cutting line 40 extends through notch 120.
As shown in FIG. 13, cutting line 40 is pulled outward from notch 120. Once
cutting line 40 is pulled away from first corner 18 toward second corner 20,
the
cutting process begins. As cutting line 40 is pulled away from second corner
20 as
shown in FIG. 14, approximately half the food product 200 is divided into
layers as
shown in FIG. 14. As cutting line.40 is pulled further away from notch 120,
cutting
line 40 becomes increasingly separated from third side 24 as shown in FIGS. 15
and
16. Once cutting line 40 becomes unattached from third side 24, the food
product 200
is completely separated into layers.
FIG. 17 shows a sleeveless layer cutting apparatus 10. Apparatus 10 includes
tray 14 with first wall 104, second wall 106, third wall 110, and fourth wall
108. Hook
190 is disposed over third wall 110 at a location adjacent to first wall 104.
Similarly,
hook 192 is disposed over second wall 106 at a location adjacent to first wall
104.
Cutting line 40 attached to hook 190 and hook 192 and suspended over bottom
100.
When food product 200 rests on bottom 100, food product can be cut into layers
by
moving hooks 190 and 192 from a location adjacent to first wall 104 to a
location
adjacent to fourth wall 108.
Another alternative embodiment of a sleeveless layer cutting apparatus 10 is
shown in FIG. 18. Apparatus 10 includes tray 14 with first wall 104, second
wall 106,
third wall 110, and fourth wall 108. Second wall 106 contains perforation line
113
extending from first wall 104 to fourth wall 108. Third wall 110 contains
perforation
line 111 extending from first wall 104 to fourth wall 108. Cutting line 40 is
suspended
between second wall 106 and third wall 110. End 41 of cutting line 40
protrudes
through the portion of perforation line 111 that is adjacent to first wall
104. End 43 of
cutting line 40 protrudes through the portion of perforation line 113 that is
adjacent to
first wall 104.
When food product 200 rests on bottom 100, food product can be cut into
layers by pulling end 41 and end 43 from a location adjacent to first wall 104
to a
location adjacent to fourth wall 108. In one embodiment, perforation lines 111
and
113 are substantially parallel to bottom 100. This configuration helps ensure
that the
lower layer 204 of food product 200 is uniform. Cutting line 40 may be
fabricated
from a variety of materials described above. Alternatively, cutting line 40
may be
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comprised of industrial tear tapes. The tear tapes can be incorporated into
tray 14
either within the tray or on the surface of the tray. Existing tear tapes are
in the range
of about 1 mm to about 0.25 inches.
FIG. 20 shows an alternative embodiment of apparatus 10 configured to cut
multiple layers. Multiple lines 40 and 41 are disposed in sleeve 12. Cutting
line 40 is
generally parallel to line 41 to create generally uniform layers.
Alternatively, lines 40
and 41 can comprise wavy or zig-zag patterns as previously discussed. Ends of
lines
40 and 41 extend through hole 121. As lines 40 and 41 are pulled outwardly
from hole
121, three layers are formed in accordance with the method described above. It
is
important to note, however, that more than two lines may be disposed in sleeve
12
while remaining within the scope of the invention.
FIG. 24 shows another alternative embodiment of apparatus 10 that is
especially useful for dividing the contents of tray 14 into portions. Tray 14
includes
sidewall 102 having a first wall 104, second wall 106, third wall 110, and
fourth wall
108. Cutting line 80 is disposed in first wall 104, bottom 100, and fourth
wall 108.
Similarly, line 82 is generally parallel to line 80 and is disposed in first
wall 104,
bottom 100, and fourth wall 108. End 81 of line 80 may be pulled away from
first
wall 104 toward and ultimately beyond fourth wall 108. During this process a
vertical
slice can be made in the contents of tray 14. Subsequently, end 83 of line 82
can be
pulled away from first wall 104 toward fourth wall 108. This process causes
another
vertical slice to be made in the contents of tray 14.
In another embodiment, end 81 of line 80 and end 83 of line 82 can each be
fixed to handle 88. As handle 88 is pulled away from first wall 104 toward
fourth wall
108, lines 80 and 82 simultaneously pull away from first wall 104, bottom 100,
and
fourth wall 108 to form separate divisions in the contents of tray 14.
To further partition the food product, additional lines 86, 87, and 89 may be
disposed in the tray 14. Line 86 is disposed in second wall 106, bottom 100,
and third
wall 110. Line 87 is also disposed in second wall 106, bottom 100, and third
wall 100.
Similarly, line 89 is disposed in second wall 106, bottom 100, and third wall
110.
Lines 86, 87, and 89 intersect each of lines 80 and 82. In one embodiment,
lines 86,
87, and 89 are parallel to one another. In a preferred embodiment, lines 86,
87, and 89
are each perpendicular to lines 80 and 82.
As discussed above, lines 86, 87, and 89 may be independently pulled from
second wall 106 to third wall 110. Alternatively, ends of lines 86, 87, and 89
may be
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fixed to handle 91. As handle 91 is moved from second wall 106 to third wall
110,
lines 86, 87, and 89 simultaneously divide the contents of tray 14.
In one embodiment, handle 88 is attached to first wall 104 using perforation
line 93. Similarly, handle 91 is attached to second wall 106 using perforation
line 95.
When the contents of tray 14 are ready to be partitioned, handle 88 is
separated from
first wall 104 along perforation line 93. Next, handle 88 is moved toward, and
ultimately past fourth wall 108 until lines 80 and 82 are completely separated
from the
contents of the container. Then, handle 91 can be separated from second wall
106
along perforation 95. Handle 91 is then moved toward and past third wall 110
until
lines 86, 87, and 89 are completely separated from the contents of the
container.
With reference to FIGS. 25 through 31, the cake-layer cutting apparatus 300
and 300' embodying the principles and concepts of the present invention will
be
described. Apparatus 300 and 300' includes sleeve 312 and 312' and tray 414
and
414'. Sleeve 312 and 312' is configured to fit inside a sidewall 402 of tray
414 and
414' as shown.
Sleeve 312 and 312' includes an elongated second side 316 terminating at a
first corner 318 and a second comer 320. A first side 322 extends from second
side
316 at first corner 318. First side 322 terminates at third corner 332.
Similarly, a third
side 324 extends from second side 316 at second corner 320. Third side 324
terminates at fourth corner 330. Second flap 326 pivotally extends from third
side 324
at fourth corner 330 which defines a fold line. First flap 328 pivotally
extends from
first side 322 at third corner 332 which defines a fold line. Sleeve 312 has
first and
second termini 328a and 326a included on first and second flaps 328 and 326
respectively. The sleeve length of sleeve 312 between first and second termini
328a
and 326a is less than the peripheral length of sidewall 402.
Cutting line 340 is attached to sleeve 312 in a plurality of locations
throughout
second side 316, first side 322, third side 324, flap 326, and flap 328. In
one
embodiment, cutting line 340 is woven through sleeve 312 in a linear fashion.
Cutting
line 340 has an extent between first and second ends 340a and 340b longer than
the
length of sleeve 312 and longer than the peripheral length of sidewall 402.
Sleeve 312' further includes first and second tabs 314a extending from the
lower edges of first and third sides 322 and 326 and a tab 314b extending from
the
lower edge of second side 316. As sleeves 312' are formed by being cut from
sheets,
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cutouts 315 are formed in the upper edges of first, second and third sides
322, 316 and
326 corresponding to tabs 314a and 315b.
Tray 414 and 414' includes an interior defined by a bottom 401 and sidewall
402. Sidewall 402 is pivotally connected to and extends upward from the
perimeter of
the bottom 401 and has a peripheral length. Bottom 401 is shown in a
rectangular
configuration, although bottom 401 can be comprised of any 2-D shape, regular
or
irregular, including circles, triangles, footballs, hearts, or any other
polygon while
remaining within the scope of the invention.
Sidewall 402 includes an elongated first side 404 terminating at first corner
412 and second corner 415. Back wall 406 extends from first side 404 at first
corner
412. Back wall 406 terminates at third corner 416. Front wall 410 extends from
first
side 404 at second corner 415. Front wall 410 terminates at fourth corner 418.
Second
side 408 is disposed between third corner 416 and fourth corner 418. In the
preferred
form, each side 404 and 408 includes a first section 405 pivotally connected
to a
second section 407. The first section 405 is pivotally connected to bottom
401. The
second section 407 includes inserts 409 opposite to first section 405 and
received in
slits 411 formed in bottom 401. Back and front walls 406 and 410 each include
first
and second tabs 413 pivotally mounted on opposite ends and received between
first
and second sections 405 and 407 of first and second sides 404 and 408. A slit
411 a is
formed at the pivotal interconnection of back wall 406 and bottom 401 in tray
414'.
Notch 420 is disposed in front wall 410 of sidewall 402 of tray 414 such that
notch 420 extends below the top surface of front wall 410. Notch 420 provides
clearance for cutting line 340 when sleeve 312 rests on bottom 401 of tray
414. Notch
420 may comprise a variety of configurations, including a slit extending from
the
upper edge as shown in FIG. 25 or an H-shaped cut spaced between the upper and
lower edges as shown in FIGS. 26 and 27. Notch 420 in the form of an H-shaped
cut
is shown as open for purposes of insertion of cutting line 340 but would be
closed
before introduction of food product 200.
In operation of the embodiment of FIG. 25, a food product can be baked in the
interior of tray 414 before placement of insert 312. Alternatively, a pre-made
food
product can be placed on the bottom 401 of tray 414. The food product can be a
cake,
intermediary food product, or any other baked goods. Next, sleeve 312 is
placed in
tray 414 so that sleeve 312 is between the food product and the sidewall 402
and in
particular that flaps 326 and 328 abut with front wall 410, first and third
sides 322 and
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324 abut with first and second sides 404 and 408, and second side 316 abuts
with
back wall 406. A space 350 is defined between second and first termini 326a
and
328a, with a distance between first and second flaps 328 and 326 and between
termini
326a and 328a being greater than 50% of a length of second side 316 and walls
406
and 410. Notch 420 is located within space 350. Further, cutting line 340
abuts with
front wall 410 within space 350 and extends through notch 420 with first and
second
ends 340a and 340b located outwardly of the interior of tray 414. In a
preferred
embodiment, sleeve 312 rests on the bottom 401 of tray 414.
In operation of the embodiment of FIGS. 26 and 27, sleeve 312' is placed in
tray 414' before food product 200 is placed in the interior of tray 414'. In
particular,
tabs 314a are inserted into slits 411 with inserts 409, and tab 3 14b is
inserted into slit
411 a, with the size of slits 411 and 411 a creating a pressure fit with tabs
314a and
314b to prevent unintentional removal. Thus, sleeve 312' does not have a
tendency to
float out of tray 414' and away from bottom 401 due to the introduction of
food
product 200 into the interior of tray 414.
With reference to FIGS. 28-31, the cutting operation of food product 200 and
sleeve 312 and 312' are located in the interior of tray 414 and 414' of
apparatus 300
and 300' will now be discussed. FIG. 28 illustrates the location of the food
product
200, sleeve 312 and cutting line 340 inside tray 414. During the cutting
operation, one
or both ends 340a and 340b of cutting line 340 is pulled outward from notch
420. As
the force on cutting line 340 overcomes the force attaching cutting line 340
to sleeve
312, cutting line 340 is pulled away from flaps 326 and/or 328 and first and
third
sides 322 and 324 as shown in FIG. 29. The portion of cutting line 340
disposed
inside food product 200 begins cutting food product 200 into layers. As
cutting line
340 is continued to be pulled, cutting line 340 is pulled away from corners
318 and
320 and away from second side 316 as shown in FIG. 30. As cutting line 340 is
continued to be pulled outward from notch 420, cutting line 340 is pulled away
from
second side 316 as shown in FIG. 31.Once cutting line 340 is pulled from
second side
316, the food product 200 is completely divided into layers.
Although the present invention has been described with reference to preferred
embodiments, persons of ordinary skill will recognize that changes can be made
in
form and detail without departing from the spirit and scope of the present
invention.
13
