Note: Descriptions are shown in the official language in which they were submitted.
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2,829.726 Description 1 30 December 2015
TITLE: COOKIE BAKING SET
TECHNICAL FIELD OF THE INVENTION
The present invention pertains generally to the field of cookie baking pans
and dessert
molds. More particularly, the present invention concerns a novel baking
apparatus for use to
selectively mold and bake food products from non leavened dough. The apparatus
described
herein may also be used to shape confectionary goods as they solidify from a
pourable state.
BACKGROUND OF THE INVENTION AND DESCRIPTION OF PRIOR ART:
Cookie and cake molds and pans have been used and are well known in the prior
art. A
typical example is the common cup cake or muffin pan. Additionally, many prior
art apparatuses
have been devised in the form of assemblies or combination sets consisting of
two or more
superposable pans. The superposable pans are configured to form one or more
hollowed interior
baking chamber when assembled in a nested relationship. The main objective
from using a
combination of pans in the form of assemblies is generally to mold and
simultaneously bake
dough of breads, cakes, cookies, or other baked goods into various shapes that
can later on be
used as containers to hold other foods as fillings. Among the several designs
that have been put
forth by prior art are:
=
U.S. Pat. No. 3,385,205 to Chester V. McCloud (issued May 28, 1968) describes
a thin
metallic baking sheet set comprising two sheets with dough displacing
recesses. The top sheet
has smaller rectangular recesses and is to be superposed on the lower baking
sheet with similar
shaped recesses of larger dimensions. Apertures in the top sheet surround the
dough displacing
recesses and prevent air from being trapped inside.
U.S. Pat. No. 3,831,507 to Donald S. Wheaton (issued Aug. 27, 1974) is
directed toward
a baking pan assembly for use to make a sandwich bun having separate upper and
lower
portions. The assembly is characterized by an arrangement of three baking pans
that can be used
to form a cylindrical bowl-like bun and a lid to be placed over it and hold
the filling inside. The
trays are to be locked together by means of lip portions curled up around each
pan's perimeter.
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U.S. Pat. No. 5,191,830 to Fred M. Jacobson (issued Mar. 9, 1993) discloses a
cup-
shaped baking apparatus comprising an upper and a lower tray with a plurality
of concave baking
chambers each. After portions of unbaked batter or dough have been placed in
the bottom tray
molds to be baked in a conventional or a microwave oven, the two trays are to
be locked together
by means of a 1-Shaped sliding rod inserted through raised eyelets on the
lower tray which
extend through corresponding openings in the upper tray.
U.S. Pat. No. 5,226,352 to Don H. Savage (issued Jul. 13, 1993) is directed
toward a cup-
shaped baking assembly comprising an outer dome shaped member and an inner
dome shaped
member. A flange extends outward from each dome member to seat the flange
extending from
the upper edge of the inner dome member. When the dome members are placed
together with the
dough between them, the -flanges are held together by a plurality of
adjustable C-clamps,
allowing dough or batter to be baked with partial escape of moisture from the
mold.
U.S. Pat. No. 5,400,698 also to Don H. Savage (issued Mar. 28, 1995) is
directed toward
a similar cup-shaped baking assembly comprising an outer dome shaped member
and an inner
dome shaped member. The molding members, though, are made from materials with
different
coefficients of heat transfer to create a heat differential while cooking.
When the dome members
are placed together with the dough between them, the flanges arc held together
by a plurality of
C-clamps, allowing dough or batter to be baked with partial escape of moisture
from the mold.
U.S. Pat. No. 6973872 132 to Fletcher Morgan (issued Dec. 13, 2005) describes
a baking
pan assembly for making multiple individual compound desserts in a
predetermined
hemispherical dome shape of the type. The pan assembly consists of a base
sheet and a top sheet.
The former (i.e., base sheet) has a plurality of dome shaped bowls to form a
base for said
compound dessert. The top sheet, consisting of a plurality of dome shaped
bowls of' a smaller
diameter, seats on the base and can be secured with a plurality of pin
fasteners, spring fasteners,
or C-clamps, to hold both sheets together and prevent separation caused by
expansion of the
baking batter of the dessert.
Similarly, U.S. Pat. No. 7150221 to Fletcher Morgan (issued Dec. 19, 2006)
describes an
apparatus for simultaneously producing multiple individual dual composition
desserts in a
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predetermined dome shape. The apparatus consists of a base tray with multiple
cavities to form a
base for said compound dessert, a rack and a plurality of removable dome
shaped bowl
assemblies which can be secured in fixed positions to said rack. Each bowl
assembly is formed
with a closed hemispherical end and an open end forming a cavity, and a cover
member which is
mounted over said open end. The cover member has an inner bowl extending
therefrom which
inserts into the cavity.
In addition to what has been cited above, numerous other superposable mold
assemblies,
have been disclosed in prior art for preparing compound desserts. However, in
spite of the many
existing designs and configurations, compound mold assemblies remain a very
uncommon and
rarely used kitchen utensil. This is largely due to the complexity associated
with their
manufacture and operation. One aspect of the complexity relates to the common
means or
features disclosed -so far- to account for the need for partial and controlled
escape of moisture
and steam without jeopardizing batter containment. Such means often consisted
in a locking
mechanism in the form of clamps, pins, flanges or spring fasteners configured
as adjustable
pressure control devices added to the assembly to limit the degree to which
batter can rise or
expand during baking. In use, this locking mechanism is rather cumbersome to
operate,
consisting of discrete components that must be assembled and attached to the
baking pan before
use. Additionally, this collage of components makes the prior art molding pan
set an expensive
bakery item that does not meet the sanitation requirements of the baking
industry.
Conventional pan sets, as such, are a contradiction in construction and design
inasmuch
as they must be lightweight and -flexible to allow for partial escape of
moisture , and therefore
relatively -fragile, to meet certain baking characteristics, but they must
also be sealed tightly
enough to ensure conformity to desired molding design and to prevent escape of
baking material
itself. The very few prior art that have disclosed incorporated apertures or
air vents as a means to
allow for partial escape of moisture (e.g., U.S. Pat. No. 3,385,205) had them
configured on the
peripheries of the molding cavity itself rather than its inside walls. The
rationale behind this
design is to prevent batter itself from escaping through these apertures.
Moreover, differential
weight or pan thickness has not been disclosed or claimed as a means to
restrict batter expansion
due to the very need for batter expansion to ensure best results. Although
this rationale and these
arrangements have been considered theoretically legitimate for the purposes of
end products
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based on leavened (i.e., expandable) baking material (such as buns, cakes, and
certain types of
bread), they are not only unnecessary for the purposes of the end product
based on which the
current invention is disclosed (i.e., non-leavened batter based cookies), but
incompatible and
inefficient. While some of the above mentioned molds are suitable for making
buns as set forth
in McCloud, attempts to process cookie dough in the same mold become fraught
with difficulty.
The difference in baking time, techniques and ingredients used for leavened
versus non-
leavened baked materials warrants the need for different apparatuses,
especially when the end
product is of a delicate size and texture. A non leavened cookie recipe (such
as the one based on
which the current invention is disclosed) is often known in the field of
dessert baking as a 1-2-3
recipe, not only due to the simplicity in its preparation but also thanks to
the simple ratios of the
common three constituent ingredients (I part sugar to 2 parts butter to 3
parts flour). This type of
cookies, commonly known as "shortbread cookies", is also prepared in a very
short period of
time requiring generally no more than 10 minutes to bake. Additionally, once
ready, cookies
need to be -literally- slipped off the pan and on a cooling rack immediately
after being removed
from the oven so that to stop the cooking process. Another difference between
leavened and non
leavened baking material, is that while the former rises and expands in shape
during baking, the
latter tends to rather spread or shrink and fill with bubbles; which is the
reason why the molding,
area needs to be sealed immediately upon the start of the baking process so
that to force the
batter to conform to the desired molding shape.
The production of a non leavened molded food product having the above
characteristics
presents certain problems that are not apparent in the formation of other
molded food products
from leavened material. In particular, the provision of relatively tender food
product that is yet
firm enough to be stuffed with other food products is not readily achieved
with the above
described molding pan sets. Such apparatuses have been found unsatisfactory
for the production
of cookies in general, and more specifically for non leavened baking material.
The provision of a
baking system dedicated for creating molded non leavened comestibles would,
therefore, be a
novel improvement to the dessert baking field. It would be a novel improvement
to design a
compound baking apparatus wherein baking chambers are sealed together by means
of
differential weight and wherein this sealing mechanism together with a
ventilation mechanism
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are integral with the trays and do not interfere with the assembly and
disassembly of the two-
piece bake ware.
Walnut cookies are, in essence, a type of a shortbread cookie and are often
prepared
based on a simple 1-2-3 non leavened batter recipe (of the type mentioned
above). They are a
compound dessert that consists of two half walnut shaped cookie shells that
are usually brought
together after being stuffed with other ingredients inside. They are a Turkish
holiday tradition
that was brought to North African cuisine, where they are known as "Jouz.a",
during the Ottoman
Empire period. They are, also, a common holiday tradition in many Eastern
European regions
(known as "Oreshki"). They remain, however, less popular and fairly new to the
North American
context, hence the lack of proper tools for making them.
The current tools used commonly for making this type of dessert entail a
number of
serious disadvantages and do not assure uniform quality and speedy production.
The standard
method used in the Eastern European and North African contexts for molding the
unfilled shells
consists in using a heavy duty stove-top mold. The mold often consists of
between 9 and up to 16
cavities where small balls of the dough are pressed down using the upper heavy
part of the mold
and cooked on the stove top. The produced shells are then filled in with
creamy fillings and
walnut pieces inside and sandwiched together (various combinations of other
fillings and nuts
are also used). This standard method is often suggested in most walnut cookie
recipes; however,
it has its major drawbacks. It is quite tedious (especially with ceramic top
stoves) and requires
continuous attending to the stove while the shells are being cooked. It is
also time consuming,
produces a lot of waste, and is quite messy for the production of larger
quantities.
Other methods were used occasionally in the North American and East European
contexts. These include:
a- Using individual walnut-shaped molds for baking in the oven, or
b- Using an electric waffle style mold.
While the latter (i.e., method b-) represents a modern twist on the
traditional tool and
remains the most time efficient for production of larger quantities, the end
product it yields
comes with a texture and taste that are rather different from the standard
shortbread cookie-like
CA 02829726 2015-12-30
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taste. This tool yields pastry shells with more of a waffle- like taste.
Method a-, on the other
hand, which produces the perfect cookie-like taste, is not only time
consuming, knowing that
each mold has to be individually and manually filled in before being placed on
a cookie sheet for
oven baking, but also yields a different shape than the shells that can be
filled inside. The non
hollow walnut half cookies it yields can only be brought together with some
spread in between
(often chocolate) that acts like glue in keeping the two parts together (in
what is more like the
Oreo cookie style). Being as such, this method does not accommodate the use of
nuts or nut
pieces as part of the filling.
Mini-muffin style mold trays with a walnut design are also used (mostly in the
North
American context) and they considerably resolve the time efficiency issue
often encountered
with individual molds. However, to produce the hollow shells, this type of
mold pan has its own
drawbacks. Without the weight of a filling, the baking crust often shrinks,
fills with air pockets,
or puffs up with bubbles, which makes it inevitable to either dock the crust
or weigh the crust
down as it bakes. With bigger pie shells, weighing the crust down often
consists in lining the
dough with parchment paper and filling it with pie Weights or dried beans (or
pennies, rice,
marbles, etc.) to hold its shape during baking. This method is not possible
with the walnut mold
tray knowing the rather small size of the numerous half walnut shaped cavities
that have to be
filled in with weights. It is even more incompatible with industrial scale
operation. Thus, a new
tool is needed to overcome the drawbacks of each of the above mentioned
methods.
It is therefore a principal object of the present invention to overcome the
shortcomings of
the prior art by designing a mold assembly which can be used for making a
shell of the above-
specified type and which is simultaneously efficient and suitable for use on
an industrial scale.
The novelty of the present invention rests in the configuration of two
supperposable trays of
similar dimensions and different weight and the associated ventilation
mechanism wherein both
the sealing and the ventilation mechanisms are integral parts of the trays
(and not added by
means of attachment). By incorporating differential weight to the pans (with
top pan being
substantially heavier than base pan), the present invention will insure best
results by forcing
dough to remain contained in mold cavities during baking and to conform to the
desired shape.
The present invention seeks to specifically solve the problem of steam
condensation during
baking by incorporating air release perforations on the mold cavities' walls
as compared to
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perforations being configured on the planar surface of top pan or the
surrounding peripheries of
the mold cavity (as in prior art). Perforated cavities will also ensure even
distribution of heat and
even cooking. The simplicity of its design and configuration, and the absence
of other
attachments and locking components facilitate cleaning of the device and
improve hygienic
conditions of its application.
SUMMARY OF THE INVENTION
The present invention is an improved walnut cookie baking assembly for
effectively and
efficiently baking cookies in a walnut shell shape that can be filled inside.
Said baking assembly
consists of two superposable pans: one top mold pan with a plurality of half
walnut shaped inner
molds designed to nest with a second base mold pan with a plurality of half
walnut shaped outer
molds. Said inner molds on said top pan engage simultaneously in the
associated outer molds on
said base mold pan and define a molding space for baking dough. Said top mold
pan is of enough
weight to press down on the dough as it bakes and has a handle projecting
upwardly from the
base and designed to fold down for ease of storage. Said inner molds on said
top pan are
con-figured with equally spaced perforations to allow heat to pass and bake
the dough uniformly.
Said outer molds on base pan are embossed with patterns that emulate the look
of natural walnut
shell patterns.
A particular object of the invention is thus to provide a mold assembly
specifically
adapted to simultaneously make multiple non leavened cookie shells which have
a concavo-
convex half walnut shell shape with a predetermined thickness and a uniform
size and shape.
Another object of the present invention is the preparation of a cookie which
retains the
uniform texture and composition experienced with flat cookie products yet
having the novelty
shape of a walnut shell for containing a confectionary material, said mold
assembly permitting
any two half walnut shaped shells to be filled and placed together to form a
whole walnut shape
in outward appearance.
It is a further object of the invention to allow for the partial escape of
moisture and gas
during baking through perforations configured on the inner molds' sloped walls
with a
dimension that inhibits the formation of steam without allowing substantial
escape of dough.
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Yet, another object of this invention is to allow preparation of cookies as
described in the
preceding objects in mass quantity in the oven of a conventional residential
kitchen. Another
object of the invention is to provide for an assembly that can be adapted for
use on an industrial
scale which is so essential from a commercial perspective.
Yet another object of the invention resides in providing an apparatus
configured to be
readily detachable and easily separated for cleaning (including dishwasher
cleaning), and
conveniently stackable for storage.
The present invention accomplishes these and other objects by providing
improved
elements and arrangements in an apparatus for the purposes described above
which are
inexpensive, dependable and fully effective in accomplishing their intended
purposes. With the
above and other objects in view, which will be apparent to those skilled in
the art, the current
invention includes certain novel features of construction and combinations of
parts which will be
apparent from the following detailed description when taken in conjunction
with the
accompanying two sheets of drawings and then pointed out in the claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a an exploded perspective view of the pan components of the present
multiple
individually sized walnut mold assembly;
FIG. 2 is a top plan view of the nested pans of the multiple individually
sized walnut mold
assembly of FIG. 1;
FIG. 3 is a perspective view from above of the components of multiple
individually sized walnut
mold assembly of FIG. 1 shown in vertically disposed exploded relationship to
one another in
accordance with the present invention;
FIG. 4 is a cross sectional side elevational view of the multiple individually
sized walnut mold
assembly taken across the lines 7'-7' of FIG. 2.
FIG. 5 is a cross sectional side elevational view of the multiple individually
sized walnut mold
assembly taken across the lines 6'-6' of FIG. 2.
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DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiment of the assembly is depicted in FIGS. 1 through 5, and
is
generally referenced by numeral 1.
Referring to FIGS. 1 to 5, a molding and baking assembly 1 according to the
invention is
adapted to shape or mold cookie baking materials into a walnut shape upon the
application of
heat to the pan. The molding assembly 1 comprises a top or shaping mold pan
10, and a
receptacle mold pan 11 formed of a relatively thin sheet of material, having a
plurality of rows of
spaced-apart half walnut shaped cavities 13 formed in the receptacle and
interconneetably
surrounded by a planar support (i.e., plane 18). Each cavity 13 in the base
mold pan in the
example shown in FIG. 3, is concavo-convex in shape and is characterized by a
downwardly
extending sloped wall 15 embossed with a walnut shell like design. Each cavity
13 is also
defined by a recessed annular orifice rim 20 formed along its upper periphery
and extending
downwardly a few millimetres from the edge where the planar surface meets the
cavity opening.
In the preferred embodiment, the planar support 19 of top mold pan 10 is
formed of a
relatively thicker and heavier sheet of material with respect to planar
support 18 of receptacle
base mold pan 11 and the cavities 12 and 13 (as shown in FIG. 3). The top mold
pan 10 is
similarly provided with a plurality of rows of spaced-apart half walnut shaped
cavities 12
complementarily formed in precise axial alignment for reception within the
receptacle cavities 13
in the base mold pan 11 when the top mold pan 10 is superposed thereon. The
cavities 12 in the
top mold pan 10 are similarly defined by downwardly extending sloped walls and
are of less
overall dimensions, including depth, than the cavities 13 on the base mold pan
11 so that when
the top mold pan 10 is superposed on the receptacle base mold pan 11 a space
or void of
predetermined dimensions is created between the surfaces defining the bottom
of the inner molds
12 and the top surface of the outer molds 13. As seen in FIG. 4 and 5, that
portion of the void,
formed by the spaced-apart cavity walls, terminates upwardly in a common plane
formed where
the bottom flat surface of top pan's plane 19 extending between cavities of
top mold pan 10
meets the top flat surface of bottom pan's plane 18 of the base receptacle pan
11 to close the
molding space. The space or void created between cavities' walls when pans are
superposed is
the area to be occupied by the cookie forming dough as hereinafter explained
17. The cavities 12
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on the top mold pan 10 are further provided with a plurality of relatively
small air vents or
apertures 14 punched or drilled through the upper inside periphery of the
sloped wall material of
each inner mold 12 to provide for the flow of heated oven air. A handle 16,
designed to fold
down for ease of storage, extends upwardly from the center plane of the top
mold pan as shown
in FIGS. 1 and 2, and serves to help in engaging pans together for placement
in the oven as well
as disengaging them upon baking completion.
The particular design of the inner molds and receptacle outer mold cavities in
the current
apparatus offers advantages over similar and related devices known in the
prior art. Simplicity of
design and operation is essential for ensuring best results namely ensuring
that end product does
not overcook or ship upon disengagement of pans. Perforations configured
throughout the walls
of inner molds make it possible to obtain a molded shell of desired texture
and uniform
thickness. Knowing the relatively small size and delicate shape of the walnut
cookie (compared
to other compound cake desserts), differential weight ensures that the inner
molds are in register
with the outer molds so that cavities 12 and 13 are concentrically positioned
throughout the
baking process. Differential weight also serves as a means to define required
amount of pressure
exerted upon mounting top mold pan and to contain dough inside molding area
and prevent it
from escaping.
While the handle, shown in FIGS. 1 and 2 as extending upwardly from the center
plane
of the top mold pan, helps in adjusting placement of top mold pan upon
engagement in base
mold pan, it can alternatively extend horizontally along the central part of
either the width or the
length sides of the top mold pan's periphery (in which case two handles are
needed on opposite
sides).
In the preferred embodiment, the apparatus may be manufactured from materials
known
in the field of cookie sheet manufacture. Although aluminum, sheet steel
and/or stainless steel is
preferred, any suitable structural material could be used in its place, as for
example, alloyed
steel, copper, brass, cast iron or even glass or ceramic, such as stoneware.
The individual
framework components need not be fabricated from the disclosed materials, but
could be
fabricated from virtually any suitable materials. In conventional molding
sets, molding cavities
typically have their upper peripheries seamed or crimped into openings
provided at interspaced
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intervals in planar support surface of pan. The inside surface of each molding
cavity 13, and the
outside surface of molding cavity 12 are preferably coated with one or more
nonstick coatings,
such as, for example, TEFLON (i.e., fluorocarbon polymers), (e.g.,
tetrafluroethlene and
fluorinated ethylene propylene) in the preferred embodiment to ease the
removal of the baked
material. Finally, while the exact number and size of the perforations should
depend on the final
measurements of each cavity, at least one set of perforations extending
laterally and radially
slightly below upper annular periphery of the inside sloped walls should make
part of each cavity
(on top mold pan).
PREFERRED MODE OF OPERATION
In the use of my walnut cookie pan, a grape sized ball or bolus of cookie
dough is
initially placed into the bottom of each of the cavities 13 of the base mold
pan 11 (preferably in a
centered position). The term "dough" as used herein in the application is
meant to encompass
non leavened cookie dough, which generally sets up in a rigid or semi-rigid
shape, but is not
intended to be limiting with regard to the nature of the other ingredients
used. Those skilled in
the art will determine a satisfactory amount of dough for the particular size
of the cavity mold
used in the forming operation. Once the appropriate amount of cookie dough has
been placed
into each cavity, the top mold pan 10 is then nested and fitted within the
base mold pan 11 with
inner molds 12 extending downwardly into the dough in base mold pan cavities
13 to restrict the
cookieshape to the desired configuration defined by the enclosure. Sufficient
pressure is applied
to top mold pan 10 to fully seat the bottom surface of the top mold pan plane
18 substantially
.flush against the top surface of base mold pan plane 19. Exerted pressure
depresses and extrudes
the dough laterally out to the side of the base pan cavities 13 and around
inner molds 12 atop
pan so as to essentially fill the bottom of the base cavity. Perforations 14
on the inside walls of
top pan cavities permit the baker to view the upper edge of the dough as it
fills the baking
chamber. They also relieve some of the internal pressure during baking and
permit the rise of air
bubbles in the dough and the escape of impounded air. This procedure is
illustrated in FIGS. 4
and 5 where, in a cross sectional view of the baking set, dough 17 can be seen
constrained
between the two parts.The assembled pans 1 are then placed in a conventional
oven and baking
proceeds in a conventional manner. As the dough bakes, it takes the internal
shape of the cavities
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13, and the external shape of the cavities 12 preserving a walnut shell finish
which adds details to
the end product.
Upon the completion of the baking step, the assembled pans are removed from
the oven.
The top mold pan 10 is removed from the assembly (lifting up from the handle)
and taken out of
its nesting position in the base mold pan 11 leaving cavities in each
individual cookie shell. The
exterior and interior surface of the top and bottom pan cavities
(respectively) are each coated in
TEFLON . This further facilitates removal of the mold without tearing or
damaging the final
baked product. The baked dough in each recess is removed and forms one half of
the walnut
cookie shell. The exterior surface of this portion resembles the exterior of a
walnut shell. This
cookie shell can be filled with a number of fillings including nuts, creams,
chocolate and many
others. Once the second half of the shell is placed on top of the filling, the
result is a walnut
shaped cookie or dessert which is filled with a specific filling and ready to
eat.
The principles, preferred embodiments and modes of operation of the present
invention
have been illustrated and described as noted above. However, it is to be
understood that the
phraseology or terminology employed herein is for the purpose of description
and not of
limitation. It will be understood and appreciated that the embodiments
illustrated and described
here should be regarded as illustrative rather than restrictive because
various modifications of
these details may be provided in putting the invention into practice within
the purview of the
appended claims. For example, it is to be understood that I am not to be
limited to the particular
proportions of the walnut design shown in the drawings, and that other nut
shapes and other
geometries of the molds 12 and 13 are possible. Additionally, the specifics of
material of which
the assembly is made can be changed without departing from the scope of the
invention.
Similarly, it is also contemplated that other embodiments of the present
invention will distribute
the plurality of cavities in an offsetting alignment, wherein adjacent rows of
cavities are parallel
along one axis but not aligned along a second axis perpendicular thereto.
Accordingly, the
invention should not be construed as limited by the disclosure of the
preferred embodiment.
Changes and variations can be made to the form, construction, arrangement, and
assembly of the
parts without departing from the spirit and scope of the invention defined by
the following
claims:
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