Note: Descriptions are shown in the official language in which they were submitted.
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Apparatus and Method for Simultaneous Cutting, Imprinting and Piercing of
Dough
FIELD OF THE INVENTION
The present invention generally relates to an apparatus and a method for
embossing and
imprinting dough. More specifically, the present invention relates to an
apparatus and a method
of simultaneously cutting out sections from a flat sheet of dough, embossing
the sections with
Coptic insignia and forming loaves for ceremonial purposes.
BACKGROUND OF THE INVENTION
A Coptic Orthodox Christian congregation has a meal together after the holy
mass as a sign
of love and communion. In in the early days a complete meal was offered after
the mass. At the
present time, the Korban, a small round loaf of bread has been substituted for
the meal. The
Korban is stamped with the "Trisagin" (the triple invocation of God as holy)
and with crosses
and has the same wheat flour, water and yeast only. The bread is leavened and
is baked
unsalted. The central part of the Korban is called "Despatikon" meaning
"Lordly" and around
the Despatikon twelve crosses referring to the twelve disciples. The
Despatikon also is pierced
with five holes referring to the spear and nails which Christ suffered. The
word "Agios" is
written in three times on the periphery of the Despatikon which represents the
"Holy Trinity".
Prior art references that relate to imprinting dough with relatively complex
patterns engraved
on a surface disposed on a rotary device include: US 177,319, US 4,276,800, US
5,162,119, US
5,388,489, US 7,845,928, US 20100159095 and US20120251690. These devices are
referred to
CA 02820270 2013-07-05
in the art as rotary cutters which are configured to cut and imprint the
dough.
Imprinting this pattern on dough and creating the finished Korban presents a
number of
challenges not addressed by the prior art. The pattern on the Korban loaf
contains raised areas,
such as the images of some of the crosses and the Coptic symbols and letters,
alongside sunken
areas; for example in some of the border outline areas and some of the cross
images. The overall
pattern must be configured in a way that the dough flows smoothly between the
raised and
sunken areas on the emboss pattern so that not to disrupt the imprinted images
on the Korban.
Furthermore, the dough must be pierced through to produce the five holes
representing the spear
and nails that pierced Christ. Simultaneously, the loaf needs to be cut out of
a sheet of dough and
areas provided for the air to escape so to prevent air from disrupting the
dough from rising to the
full loaf. Also, the type of dough that contains only flour water and yeast
tends to be particularly
unstable if left unbaked for long periods of time.
SUMMARY OF THE PRESENT INVENTION
In one aspect of the present invention, an apparatus configured for
concurrently cutting,
imprinting and piercing of a sheet of dough to produce imprinted loaves, the
dough consisting of
flour, water and yeast, the apparatus comprises: a cylindrical member mounted
on an axle, the
cylindrical member having a length; at least one emboss pattern engraved onto
a surface
disposed on the cylindrical member, the emboss pattern being placed inside a
frame encircled by
an outwardly extending border, the border constituting cutting edge lips
protruding above the
surface, the emboss pattern containing a plurality of shaped projections that
protrude outwardly
and are elevated above the surface on which the emboss pattern is placed, the
emboss pattern
also containing recessed areas below the surface on which the emboss pattern
is placed; and a
plurality of outwardly projecting pins contained within the emboss pattern,
the pins being affixed
on the surface, wherein downward pressure applied onto the cylindrical member
is configured to
cause the cylindrical member to engage a sheet of dough in a manner such that
simultaneously
the border lip slices out a loaf from the dough, the emboss pattern encircled
by the border lips
imprints the loaf and the pins contained within the emboss pattern pierce the
loaf.
In another aspect of the present invention, a method for producing loaves each
imprinted
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with a pattern containing a plurality of raised areas and a plurality of
recessed areas the method
comprises: providing an apparatus configured for concurrently cutting,
imprinting and piercing of a sheet
of dough to produce imprinted loaves, the dough consisting of flour, water and
yeast; loading the cylinder
member onto the sheet of dough in a manner as to simultaneously sever 5
individual loaves from the sheet
of dough, imprint each loaf with the emboss pattern and pierce the dough by
the pins contained within
the each emboss pattern; heating each loaf to a temperature between about 90
degrees F to about 180
degrees F through contact with a heated emboss pattern to initiate a process
of rising and for stabilizing
the dough; and baking the loaves in the oven to complete the baking process.
In another aspect, there is provided an apparatus configured for manually and
concurrently
cutting, imprinting and piercing of a sheet of dough to produce imprinted
loaves, said dough consisting
of flour, water and yeast, said apparatus comprising: a cylindrical member
mounted on an axle, said
cylindrical member having a length; a plurality of embossing patterns engraved
onto an inner surface
disposed on the cylindrical member, each of said embossing patterns placed
inside a frame, each of said
embossing patterns encircled by an outwardly extending border, said border
constituting a cutting edge
protruding above the inner surface, said embossing patterns containing a
plurality of shaped projections
that protrude outwardly and are elevated above the surface on which the
embossing patterns are placed,
said embossing patterns also containing recessed areas below the inner surface
on which the said
embossing patterns are placed; and each of said embossing patterns having a
circular border that
protrudes, relative to the engraved surface by a height ranging from about 0,4
inches to about 0,45 inches,
each of said embossing patterns are elevated relative to outer surfaces on the
cylinder member outside
the respective frame by between about 0,15 inches to about 0,25 inches and
contains a plurality of areas
that are recessed from the inner surface of each embossing pattern, said
recessed areas being arranged in
a circle on the periphery of each embossing pattern, said areas forming
symbols representing Coptic
script encircling a plurality of cross patterns, said recessed areas being
configured to form corresponding
raised areas on a respective loaf in the course of imprinting the loaf; said
circular borders arranged in
rows, said rows are offset and interleaved; a plurality of outwardly
projecting pins contained within said
embossing patterns, said pins being affixed on said inner surface, and
protrude from about 0,38 inches to
about 0,43 inches above said engraved surface; and wherein downward pressure
applied manually to said
axle of said cylindrical member is configured to cause said cylindrical member
to engage a sheet of
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dough in a manner such that simultaneously a cutting edge slices out the
respective loaf from the dough
sheet, the respective embossing pattern encircled by a cutting edge imprints
the respective loaf and the
respective pins contained within an embossing pattern pierce a respective
loaf.
In another aspect, there is provided an apparatus configured for manually and
concurrently
cutting, imprinting and piercing of a sheet of dough to produce imprinted
loaves, said dough consisting
of flour, water and yeast, said apparatus comprising: a cylindrical member
mounted on an axle, said
cylindrical member having a length; a plurality of embossing patterns engraved
onto an inner surface
disposed on the cylindrical member, each of said embossing patterns placed
inside a molded frame, each
of said embossing patterns encircled by an outwardly extending border, said
border constituting a cutting
edge protruding above the inner surface, said embossing patterns containing a
plurality of shaped
projections that protrude outwardly and are elevated above the surface on
which the embossing patterns
are placed, said embossing patterns also containing recessed areas below the
inner surface on which said
embossing patterns are placed; the plurality of areas are recessed from a
surface of each embossing
pattern, said recessed areas being arranged in a circle on a periphery of each
embossing pattern, said
recessed areas forming symbols representing Coptic script encircling a
plurality of cross patterns, said
recessed areas being configured to form corresponding raised areas on a
respective loaf in the course of
imprinting the loaf; a plurality of outwardly projecting pins contained within
said embossing patterns,
said pins being affixed on said surface; herein the projecting pins protrude
from about 0.38 inches to
about 0.42 inches above the inner surface such that the projected pins are
raised to a level below the
height of the border encircling the respective embossing patter; and wherein
downward pressure applied
manually to said axle of said cylindrical member is configured to cause said
cylindrical member to engage
a sheet of dough in a manner such that simultaneously a cutting edge slices
out the respective loaf from
the dough, an embossing pattern encircled by a cutting edge imprints the
respective loaf and the
projecting pins contained within an embossing pattern pierce the respective
loaf, wherein the inner
surface inside the respective molded frame is elevated relative to outer
surfaces on the cylinder member
outside the molded frame by between 0.15 inches to about 0.25 inches..
These and other features, aspects and advantages of the present invention will
become better
understood with reference to the following drawings, description and claims.
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BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a view of an individual imprinting plate for forming a Korban loaf
from a sheet of
dough in accordance with an embodiment of the present invention;
Figure 2 shows rows of imprinted loaves on a sheet of dough with the image of
the Korban
using the device for cutting, imprinting and piercing dough.
Figure 3 is an isometric view of the rotary cylinder member containing the
emboss patterns
inside respective frames according to an embodiment of the present invention;
Figure 4 is cross sectional view of the imprinting plates mounted inside the
frames of the rotary
cylinder member;
Figure 5 is a perspective view of a power driven rotary cylinder member for
cutting,
imprinting and piercing of dough in accordance with the invention;
Figure 6 is an isometric exploded view of the brackets to mount the rotary
cylinder in position
as depicted in Fig. 5;
Figure 7 shows an imprinting plate mounted on a handle that may be used to
cut, imprint and
pierce Korban loaves individually;
Figure 8 is a cross sectional view embodiment of Fig. 7 to show the relation
of the imprinting
plate, the piercing pins, and the cutting edge of the frames;
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Figure 9 is a view of the Korban loaf ready to be offered to the congregation;
Figure 10 is a view of the arrays of the emboss patterns engraved onto the
cylinder member
according to an embodiment of the present invention;
Figure 11 is a view of an individual emboss pattern engraved onto the surface
of the cylinder
member surface according to an embodiment of the present invention;
Figure 12 shows a cutaway view of raised emboss elements and recessed areas on
the
embossed pattern surface according to an embodiment of the present invention;
and
Figure 13 is a depiction of shaped emboss-pattern components according to an
embodiment
of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description is of the best currently contemplated modes
of carrying
out exemplary embodiments of the invention. The description is not to be taken
in a limiting
sense, but is made merely for the purpose of illustrating the general
principles of the invention.
The persent invention relates to a rotary cylinder member configured for
rotating and for
concurrently cutting, imprinting and piercing a sheet of dough consisting of
flour, water and
yeast to produce imprinted loaves. To accomplish this, the rotary cylinder
member contains at
least one emboss pattern placed inside a frame disposed on the surface of the
rotary cylinder
member. In the preferred embodiment, the emboss pattern is engraved onto the
surface of the
cylinder member contained within the frame. In the preferred embodiment of the
present
invention, a circular shaped frame is molded onto the cylinder member, but
other types of frames
as well as various attachment means to the cylinder member also fall within
the scope of the
present invention. The frame comprises borders that encircle the emboss
pattern. The borders
have edges raised above the surface of the cylinder as well as above that of
the emboss pattern
and are configured to cut a sheet of dough when sufficient pressure is applied
onto the cylinder.
The pattern is configured to produce a plurality of images on the dough sheet
that represent
Coptic religious symbols including Coptic letters, crosses, circles and
squares. These images are
created by a combination of recessed areas and protrusions on the emoss
pattern that are
imprinted and transferred onto the Korban loaf surface. In another embodiment,
the pattern may
be engraved on plates placed inside their respective molded frames. The
borders may form a
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round cup shape; however elliptical shapes with the major axis arranges
longitudinally on the
cylinder and the minor axis arranged axially also falls within the scope of
the present invention.
In the preferred embodiment, the rotary cylinder is rotated while it is
pressed onto a sheet of
dough. The sheet may be moving on a conveyor or be stationary while the rotary
cylinder
member rotates and engages the dough. Vertical pressure is applied onto the
rotary cylinder to a
sufficent extent so that the borders of each frame cut through the dough to
produce individual
loaves and simultaneously the emboss pattern is imprinted on the dough
surface. In the preferred
embodiment of the present invention, the cylinder member including the molded
frames and
emboss patterns are heated to a range of temperatures between 90 ¨ 180 degrees
depending on
speed of cylinder rotation and thickness of the dough sheet. The contact
between the heated
molded frames and emboss patterns with the dough initiates a process known as
par-baking, i.e.,
the process of rising and for stabilizing the dough. It will be appreciated by
those skilled in the
art that heating the emboss pattern is best accomplished by placing electrical
resistors inside the
cylinder member heated by passing an electrical current through the resistors
and providing heat
Is
transfer means to the surface of the cylinder member; however other heating
means fall within
the scope of the present invention as well.
The frames are arranged spacially in such a manner as to minimize the space
between
adjacent molded frames thereby maximizing the number of loaves that are
produced in the
process. A number of frame arrangements fall within the scope of the present
invention.
Figure 10 shows arrays of molded frames containing the emboss patterns
arranged in rows
arranged axially wherein the border of each molded frame contacts that of an
adjacent molded
frame in that row. The molded frames of rows adjacent to the first row are
placed in staggered
positions relative to those in the first row. A cylinder member may have three
rows of molded
frames; however, fewer than three and more than three rows also fall within
the scope of the
present invention. Each row contains five emboss patterns each contained
within its cup-shaped
borders; however, fewer than five and more than five embossed patterns also
fall within the
scope of the present invention. In Figures 2 and 3, the rows are arranged
longitudinally with five
emboss patterns in each row having four rows per cylinder in Figure 2 and five
rows in Figure 3.
The surface inside each molded frame may be elevated relative to surfaces on
the cylinder
member outside the molded frame by between about 0.15 inches to about 0.25
inches. The
borders around each individual emboss pattern are raised relative to the
engraved surface by a
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height ranging from about 0.4 inches to about 0.45 inches. The imprinting
plates include five
pins which extend through the surface of the respective plates and pierce five
spaced holes in
the dough. The pins also protrude from about 0.38 inches to about 0.43 inches
above the
engraved surface. The pins preferably are raised to a level below the borders
as illustrated in
Figure 12.
As the cylinder member rotates across the dough, the border lips of the emboss
patterns
are pressed against the dough sheet with sufficient force to separate out
individual loaves
from the dough, while the emboss pattern in each frame imprints the
corresponding loaf and
the pins of each emboss pattern pierce the loaf in their designated spots.
Figures 1 - 13 illustrate the various components and embodiments of the
invention.
Figures 1 ¨ 9 generally relate to imprint plates used for imprinting the
Korban image on the
dough, while Figures 10 ¨ 13 generally relate to the embodiment of the emboss
pattern
engraved directly onto the surface encircled by the molded frame.
Figure 1 shows the circular imprinting plate 12 for use in forming a Korban
loaf 15 to be
used at the Coptic communion meal. Symbols and characters 14 are engraved to
form the
words Holy or "Agios" three times adjacent the periphery of the round Korban
loaf 15. It will
be readily appreciated that the raised characters appearing on the Korban
constitute the mirror
image of the emboss pattern on the plate 12. A large cross formed in the
center of the plate
represents Jesus Christ. Also, the central part of the imprinting plate 12 is
embossed to imprint
twelve crosses, generally labeled 16, on the loaf. These are in reference to
the twelve disciples.
Also in the center of the plate, five pins generally labeled 18 (also see
Figs. 4 and 8) extend
from the surface of the plate 12 to pierce the loaf and are in reference to
the five wounds
suffered by Jesus Christ on the cross. The Korban loaf is circular in shape of
the sun and refers
to Jesus Christ. Thus, each part of the Korban loaf is formed to have
religious connotation.
Fig. 2 depicts a flat sheet of dough 19 on which the Korban loaves 15 are
formed mounted
on a table or conveyer belt, as will be further explained.
Fig. 3 shows a preferred embodiment of the apparatus configured for
concurrently cutting,
imprinting and piercing of a sheet of dough 20 comprising a cylinder 29
mounted on an axle
26. A plurality of emboss patterns frames 22 mounted in spaced, longitudinally
extending rows,
generally labeled 23 are mounted on the periphery of the cylindrically shaped
member 20 for
forming the Korban loaves. In the embodiment shown, five molded frames 22 are
mounted on
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each of the rows, and five rows are mounted on the periphery of cylinder
member 20. Thus, a
total of twenty five molded frames 22 are depicted in Fig. 3. The molded
frames 22 in the rows
are slightly offset or interleaved, as depicted in Fig. 3 in order maximize
the use of the dough,
i.e., to minimize waste. The edges of the border 36 that encircle frames 22
are sufficiently sharp
to sever the dough 19. The dough 19 is severed, as depicted in Fig. 2 to cut
and form
individual circular loaves on the sheet of dough. In the embodiment of Fig. 3,
the axle extends
outwardly from the ends of the cylinder 29 and forms a handle thus enabling an
operator to
position and move/roll the cylinder member 20 over a sheet of dough to form
the Korban
loaves.
In the embodiment of Fig. 3, five rows of molded frames 22 encircled by
borders 36 are
mounted to rotate on axle 26. The molded frames 22 are thus rotated by
cylinder 29 and axle
26 to provide a rotating sequence for the cylinder member. As the axle 26 is
rotated and the
molded frames 22 on cylinder 29 come in contact with the dough, the border 36
of the molded
frames 22 will cut successive circles of dough 15 adjacent one another. The
dough between the
loaves 15 is then removed from the sheet 19 and the individual loaves 15 are
baked to thus
forming the Korban loaves. As stated above, the cylinder member 20 comprises
multiple
emboss patterns. It should be appreciated that more or fewer frames can be
mounted on the axle
dependent on the requirement of the number of loaves to be made, and the
diameter and length of
the cylinder member 20. Note that Fig. 3 depicts one embodiment of the
cylinder member 20
comprising twenty five molded frames 22. In Fig. 3, the axle 26 may comprise a
handle which
may be operated manually. Briefly refer to Fig. 5 that depicts a power driven
cylinder member
25. The cylinder member molded frames 22 are identical for both the manually
driven cylinder
member and the power driven cylinder member. In the preferred embodiment, the
frames 22 are
identical and each molded frame 22 functions separately to form an identical
loaf 15. A
description of one molded frame 22 thus applies to all the other frames 22.
Referring now more
particularly to Figs. 1, 4 and 8, the circular Korban imprinting plate 12 is
shown mounted and
positioned inside the molded frame 22 of the cylindrical member 20. Basically,
the imprinting
plate 12 is mounted inside frame 22 in a relatively recessed position to
enable the cut to be
made on the sheet of dough 19 by the sharp edges of the frames and yet permit
the forming of
the symbols and characters on the top surface of the dough. The dough 19 is
approximately one-
half inch in thickness. As stated above, the dough is made of unsalted white
wheat flour,
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leavening and water only and rolled into a flat sheet 19.
Fig.4 is a cross section view of a molded frame 22 such as shown in Fig. 3;
the molded
frame in Fig. 4 is oriented vertically to more clearly show the structure, and
the extension of
the piercing pins. The border of the molded frame 22 extends downwardly and
has a sharp
edge 36 for severing the sheet of dough 19. The Korban forming plate 12 is
mounted in the
center of the frame 22 by suitable means such as screws at a position which
accommodates the
thickness of the sheet of dough. In one embodiment, the plate is mounted one-
half inch from
the cutting edge of the molded frame 22, since the sheet of dough is rolled to
be approximately
one-half inch in thickness. As described above, the Korban imprinting plate 12
is embossed
with symbols and characters on its surface 17 that impinges on the dough 19 to
imprint the
symbols and characters on the surface of the dough while not damaging the
surface of the
dough. Pins 18 on imprinting plate 12 extend outwardly to pierce the dough to
provide the
symbolism described above. The interior edges of the molded frame 22 are
angled slightly
outwardly to enable clean withdrawal of the molded frame 22 from the cut dough
piece as the
molded frame 22 is moved upwardly after cutting the dough.
Fig. 5 depicts the cylinder member 25 including multiple molded frames 22
mounted on an
axle 26 (not shown in Fig. 5, but similar to axle 26 of Fig. 3 of cylinder 29)
wherein the axle 26
and therefore cylinder member 25 is driven by an electric motor of any
suitable known design,
not shown. Note that cylinder members 20 and 25 and the frames 22 thereof are
identical
except for the means of driving the units. Fig. 5 show the cutter 25 mounted
on a belt conveyer
system 38. The cylinder member 25 mounted over a conveyer belt 39 that is
carrying a sheet of
dough 19.
Fig. 6 depicts convenient brackets for mounting the cutter 25 on the conveyer
system 38. A
threaded adjustable rod 42 includes a socket 43 for receiving axle 26 of
cylinder member 25.
Plate 45 and nuts 46 conveniently and removably affix the rod 42 to the
conveyor system 38.
There are two sets of brackets, one for each side of the conveyor. Two
mechanisms may be used
for driving the cylinder member. The first mechanism adjusts the cylinder
member to engage
the conveyer belt and rotate as the belt moves; the second mechanism connects
the cylinder
member directly to the conveyer motor through a timing belt.
As the molded frame 22 is moved over the dough, multiple dough pieces
(Korbans) will be
cut at a time. While in the embodiment shown, five rows of frames and five
columns of frames
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are shown, it is envisioned that from one to four columns of frames and one to
five rows of
molded frames may be mounted on the cylinder member, dependent on the number
of loaves
required. Importantly and as depicted in Figs. 2, 3 and 5, multiple loaves are
cut, imprinted and
pierced during on full pass (rotation) of the molded frames 22 of cylinder
member 20. Further,
the multiple operation of imprinting, piercing and cutting of each Korban loaf
is done
concurrently. A multiple item rotary cutter as in claim 1 wherein said
imprinting plates are
formed of metal such as stainless steel or aluminum and said plates are heated
when applied to
cutting the dough whereby said heated metal gelatinize the starches in said
dough thereby
making the symbols and character more permanent and enhances their visibility.
The imprinting plate 12 may be made of stainless steel, aluminum, plastic or
wood. When
made of stainless steel and aluminum the imprinting plate 12 can be heated, so
that as the
surface of the plate impinges on the dough, it gelatinize the starch and makes
the symbols and
the characters more obvious and permanent. The symbols and characters will not
fade during
the baking process. In addition, the molded frames 22 can be coated by non-
stick material to
ease the release of the dough. Further, the position of the imprinting plate
12 may be moved
within the sides of molded frame 22 to be adapted for use with other types and
thicknesses of
dough.
Figs. 7 and 8 show a hand held tool 40 for piercing, imprinting and cutting
Korban loaves
when the number of loaves required is not large. The molded frame 22 shape is
similar to that
used on the cylinder member but attached to a handle. Note again, that exactly
five piercing pins
38 are mounted in each molded frame 22 as depicted in Figures I, 4 and 8
respectively show
only two and three pins because of the section angle being viewed. While the
invention has
been particularly shown and described with reference to preferred embodiments
thereof, it
will be understood by those skilled in the art that various changes in form
and details may
be made therein. This embodiment is presented for illustration purposes.
In Fig. 10, the molded frames 55 containing the emboss patterns are shown in a
front
view arranged in rows that are engraved axially onto the cylinder member
(shown in broken
Ii nes).
Fig. 11 shows a single molded frame 55 containing four holes 44 included in
the emboss
pattern. The holes 44 are used to vent out that may build up in the process of
imprinting the
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dough. It is noted that the Coptic letters and symbols are arranged in a
circle at the perimeter
of the emboss pattern while the cross designs are in situated in the center.
The letters and
symbols are generally sunken below the surface of the emboss pattern and
produce the
desired imprints on the Korban loaf in the form of raised symbols and letters.
The cross
designs may be made of a more complex combination of protrusions and recessed
areas that
produce the opposite image forms on the Korban.
The sectioned side view of Fig. 12 shows the emboss pattern inside borders 52
having a
combination of raised areas and sunken areas in relation to the emboss pattern
surface 41
highlighting the pins and dimensions of the molded frame components.
to Figure 13 shows raised emboss elements 47 and sunken areas 49 areas in
relation to the
emboss pattern surface 41. The emboss pattern elements 47 are preferably
shaped in a way
that the dough flows smoothly around the elements to avoid the formation of
ridges and
rough areas on the Korban loaf. As can be seen, the sides of the elements are
angled, also
referred to in the art as "radiused" such that the top is narrower than the
base and the ends
are rounded. Likewise, the sunken areas do not contain any sharp angles.
The embodiments presented herewith relate to a rotating cylinder configured
for cutting
out loaves from a sheet of dough while simultaneously imprinting and piercing
each loaf. It
should be understood that processes wherein these actions are accomplished
manually are
not precluded by the present invention. For example, an individual loaf may be
processed by
a hand held device such as one shown in Figure 7, or a vertical press
containing multiple
frames molded onto a plate configured for being pressed onto a sheet of dough
so to produce
multiple imprinted and pierced loaves.
It should be understood, of course, that the foregoing relates to exemplary
embodiments of
the invention and that modifications may be made.
