Patent Application
20080217341
The present disclosure is generally directed to food technology. More specifically, the present disclosure is directed to hygienic baking pans and methods for producing same.
There are a variety of baking pans currently on the market. However, most of the existing baking pans are unable to provide good release of a food product without having a non-stick agent or coating applied thereto. Similarly, existing baking pans may include cracks or crevices in the surface of the pan that prevent the baking pan from having a surface that meets certain hygienic standards.
Therefore, there is a need to provide improved hygienic baking pans and methods for producing and using same.
The present disclosure generally provides baking pans, methods of manufacturing same and method of using such pans. The apparatuses of the present disclosure comprise a panel having a continuously formed structure. The apparatuses may also comprise a frame joined to the panel. The panel may be made from a metal material and may have a plurality of concave molds formed therein. The present disclosure may be used, for example, for improved release of a food product, for producing a food product having an increased depth, and for providing a hygienic surface for baking a food product.
Pursuant to an embodiment of the present disclosure, an apparatus for preparing food products is provided. The apparatus may include a panel having a continuously formed structure comprising at least two sides and having a frame joined to the panel. The frame and the panel further define a gap therebetween. The gap allows for convenient cleaning of the apparatus and prevents build-up of a food product during or after use of the apparatus.
In an embodiment, the frame may comprise at least one stainless steel support bar. However, the frame may also comprise three support bars. The panel may have a top surface and a bottom surface.
In an embodiment, the panel may further comprise two sides and two edges. Each of the two sides may include a double fold. The double fold may comprise a first fold that orients the side of the panel from a substantially horizontal direction to a substantially vertical direction, and a second fold that orients the panel from a substantially vertical direction to a substantially horizontal direction extending inward from the side. Similarly, each of the two edges may include a single fold. The single fold may comprise a first fold that orients the edge of the panel from a substantially horizontal direction to a substantially vertical direction extending downward from top surface of the panel.
In an embodiment, the frame comprises three support bars where one support bar is joined to each of the single folds on the two edges of the panel, and one support bar is joined to the bottom surface of the panel.
In an embodiment, the gap is further defined by a support bar joined to a bottom surface of the panel and the double fold. Further, the gap may extend for a majority of a junction between the frame and the panel.
In an embodiment, the panel is made from a material having non-stick properties relative to the food product being prepared. For example, in an embodiment, the material is stainless steel.
In another embodiment, an apparatus for preparing food products is provided. The apparatus includes a panel having a continuously formed structure comprising at least two sides and defining exposed surfaces. The exposed surfaces are fully accessible and so constructed and arranged as to not define any points of accumulation.
In an embodiment, the panel may further comprise a plurality of concave molds formed therein.
In an embodiment, the panel also comprises a frame joined to the panel defining a gap therebetween and exposed surfaces. The exposed surfaces are fully accessible except at junctions where the frame is joined to the panel and are so constructed and arranged as to not define any points of accumulation.
In yet another embodiment, an apparatus for preparing food products is provided. The apparatus includes a stainless steel panel having a continuously formed structure comprising at least two sides.
In an embodiment, the stainless steel panel may further comprise a plurality of concave molds formed therein.
In an embodiment, the apparatus further comprises a frame joined to the panel defining a gap therebetween. The frame may comprise at least one support bar.
In still yet another embodiment, an apparatus for preparing food products is provided. The apparatus includes a panel comprising a top surface, a bottom surface, a plurality of concave molds and having a frame joined to the panel. The concave molds may extend downward, for example, at least 12 millimeters from the top surface of the panel.
In an embodiment, the concave molds have a substantially semi-cylindrical shape. The molds may also have a substantially smooth surface. The concave molds may have dimensions of from about 80 millimeters to about 96 millimeters by about 18 millimeters to about 22 millimeters by about 10 millimeters to about 14 millimeters. The molds may also be spaced from about one inch to about two inches apart.
In an embodiment, the panel is stainless steel.
In an embodiment, the panel further comprises from about 8 to about 14 columns and from about 4 to about 8 rows of concave molds.
In an embodiment, the frame may comprise at least one support bar.
In another embodiment, methods for manufacturing apparatuses for preparing food products are provided. The methods include manufacturing a single continuous sheet of metal material to form a tray having a top surface and two sides, forming the metal material sheet to form a plurality of concave molds therein, and joining a frame to the metal material sheet, wherein a gap is formed between the frame and the metal material sheet.
In an embodiment, the metal material is stainless steel.
In an embodiment, the metal material sheet may be formed by stamping. Similarly, the metal material sheet may also be formed by hydroforming.
In an embodiment, the method further comprises annealing the metal material sheet.
In an embodiment, the sides of the metal material sheet may be folded with a double fold. Similarly, two edges of the metal material sheet may be folded with a single fold.
In an embodiment, the method further comprises using a brazing paste to join the frame to the metal material sheet. The brazing paste may be a bronze brazing paste.
An advantage of the present disclosure is to provide a hygienic baking pan.
Another advantage of the present disclosure is to provide a hygienic baking pan that provides concave molds.
An additional advantage of the present disclosure is to provide a hygienic baking pan that includes a hygienic surface and frame.
A further advantage of the present disclosure is to provide a hygienic baking pan having increased rigidity.
An advantage of the present disclosure is to provide improved pans for preparing food products.
Another advantage of the present disclosure is to provide improved methods for making pans for preparing food products.
Still yet another advantage of the present disclosure is to provide improved methods for preparing food products.
Additional features and advantages are described herein, and will be apparent from, the following Detailed Description and the figures.
The present disclosure is generally directed to food technology. More specifically, the present disclosure is directed to baking pans and methods for producing and using same. For example, the hygienic baking pan of the present disclosure allows for several advantages in preparing a food product including, for example, increased production, improved product size and improved hygienic surfaces. In various embodiments, the present disclosure provides an increased numbers of concave molds per hygienic baking pan, increased depths of the concave molds and improved hygienic surfaces. While the Figures of the present disclosure illustrate embodiments wherein the hygienic baking pan comprises a plurality of concave molds, it is understood that the hygienic baking pan need not comprise concave molds, as will be discussed further herein.
As shown in
In the same way, the dimensions of the hygienic baking pan 10 may also vary. For example, in an embodiment, the hygienic baking pan 10 has dimensions of about 26 inches by about 18 inches. However, the hygienic baking pan 10 may also have larger or smaller dimensions as desired and/or depending on production specifications. For example, the hygienic baking pan 10 may also have dimensions from about 22 inches to about 30 inches by about 16 inches to about 20 inches. The frame 22 in the illustrated embodiment of
The panel 12 of the hygienic baking pan 10 may have a top surface 12a, a bottom surface 12b, sides 14, 15, and edges 16, 17, as shown in
The hygienic baking pan 10 may comprise a panel 12 having a substantially flat top surface 12a and a substantially flat bottom surface 12b. In this embodiment, the hygienic baking pan 10 may be used to prepare a food product by, for example, placing an uncooked food product on the top surface 12a of the panel 12 and then placing the hygienic baking pan 10 into an oven to cook the food product. It is to be appreciated, however, that the panel 12 need not be substantially flat and may take on other shapes or forms, as will be discussed herein below.
In an embodiment, the panel 12 may be made of a metal material 18. The metal material 18 may be a sheet metal, the shape of which is capable of being deformed. Forming sheet metal into complex shapes can involve a number of distinct processing steps. For example, the concave molds may be formed by any shaping process known in the art including conventional metal processes such as molding, forging, casting, hydroforming and stamping. Hydroforming, for example, is a specialized type of die forming that uses a high pressure hydraulic fluid to press room temperature working material into a die. Hydroforming allows complex shapes with concavities to be formed, which would otherwise be difficult or impossible with traditional forming methods. In an embodiment, however, the metal material 18 is formed by stamping, as will be discussed herein below.
The metal material 18 may have a thickness 18a in the range of from about 0.7 millimeters to about 0.9 millimeters. Preferably, the metal material 18 has a thickness 18a of about 0.8 millimeters.
Further, the metal material 18 may be any metal material including, but not limited to, tin, aluminum, steel, tempered steel, spring steel, aluminized steel, stainless steel, or the like, or combinations thereof. In an embodiment, the metal material 18 is stainless steel. Although some of the embodiments discussed herein below include a panel 12 made from stainless steel, the skilled artisan will appreciated that the panel 12 need not be made from stainless steel and may be made from other suitable metal materials 18 such as, but not limited to, those discussed herein above. It should also be appreciated, however, that the material used to make the panel 12 should be a material having non-stick properties relative to the food product being prepared. In other words, the food product being prepared should not stick to the panel 12 during release of the food product from the panel 12.
The use of stainless steel as the metal material 18 is advantageous because stainless steel does not require a non-stick agent or coating to be applied to the hygienic baking pan 10 to have good release of the food product after baking and to prevent corrosion of the metal material 18. In contrast, when baking pans are made using, for example, a spring steel or an aluminized steel, the pans may require coating with a non-stick agent or coating, such as TEFLON® (i.e., fluorocarbon polymers) or a silicone glaze to allow for easy removal of the food product after baking and to prevent corrosion. However, after many uses of a pan having a non-stick coating, the coating may wear down and require re-coating, it may flake off and be ingested by the consumer, or it may be scratched thereby reducing the effectiveness of the coating. In addition, pans having non-stick coatings generally may not be wiped down or scraped after use for the reasons previously discussed.
In contrast, however, pans made of stainless steel may be wiped or scraped after use with no deterioration of the quality of the pan surface. Moreover, stainless steel provides a microstructure that is free of cracks and crevices found in certain other metal materials 18 used to manufacture baking pans currently on the market. For example, baking pans made from metal materials 18 that are slightly porous or have micro-sized cracks and crevices allow food to build-up in those surface defects. In other words, defects in the surface of a baking pan including, but not limited to, pores, cracks, crevices and the like can form points where typical food products used in preparing a final food product may collect and cause build-up of a food product so as to create a potential microbiological hazard. As a result, baking pans having defects in the surfaces of the baking pan typically do not provide a completely hygienic baking pan surface. Consequently, such baking pans may not provide a completely hygienic final food product free of possible microbiological hazards. As used herein, to “not define any points of accumulation” means a surface, device, or apparatus does not provide an area or location where sufficient food debris can collect to create a potential microbiological hazard through regular use.
On the other hand, baking pans made from stainless steel are more hygienic because they lack the cracks and crevices found in baking pans made from certain other metal materials 18 and can, therefore, provide a hygienic food product. Generally, baking pans made from stainless steel are also non-porous, corrosive resistant, durable, maintenance free, non-toxic and cleanable. Moreover, baking pans made from stainless steel also provide a desired microstructure having good wear resistance that allow the baking pan to be wiped or scraped after use of the baking pan.
Similarly, in an embodiment, the panel 12 may define exposed surfaces. The exposed surfaces may be fully accessible to a user and so constructed and arranged as to not define any points of accumulation as discussed herein above. In this embodiment, the full exposure of the exposed surfaces of the panel 12 allows a user to physically remove any build-up of a food product that might occur during use of the hygienic baking pan 10. In this way, the structure of the hygienic baking pan 10 further contributes to the preparation of an hygienic food product.
In an embodiment, the panel 12 may comprise a plurality of concave molds 20, as is shown in
The concave molds 20 may be formed by shaping a metal material 18 of a predetermined size. In an embodiment, and as shown in
In an embodiment, the concave molds 20 may have dimensions from about 80 millimeters to about 96 millimeters by about 18 millimeters to about 22 millimeters by about 10 millimeters to about 14 millimeters. In an embodiment, however, the concave molds 20 have, for example, dimensions of 85 millimeters by 20 millimeters by 12 millimeters. The skilled artisan will appreciate that the dimensions of the concave molds 20 may be larger or smaller depending on the desired size and shape of the food product.
Because of certain complexities in forming, for example, stainless steel by methods such as stamping or hydroforming, and because of stresses in the metal material caused by such forming, it is generally difficult to provide, for example, stainless steel baking pans having concave molds 20 with depths greater than 10 millimeters and spaced less than about two inches apart. An advantage of the present disclosure, however, is the ability to provide concave molds 20 that are either stamped or hydroformed in a stainless steel panel 12 where the concave molds 20 may have depths from about 10 millimeters to at least 12 millimeters, or even greater. Further, the concave molds 20 may be spaced from about one inch to about two inches apart. In an embodiment, the concave molds 20 may be spaced, for example, one inch apart, as is shown in
Further, in an embodiment, the concave molds 20 may have a depth of at least 12 millimeters. Providing a hygienic baking pan 10 having such concave molds not only allows for a greater depth and wider range of sizes of the food product, but also allows for a greater throughput of product in each batch prepared with the hygienic baking pan 10, thereby increasing production yields.
The hygienic baking pan 10 may have any number of concave molds 20 formed in the panel 12. The concave molds 20 may also be arranged in the panel 12 in any pattern desired. In
In an embodiment, and as discussed previously, the concave molds 20 may be formed by stamping the metal material 18 using an industrial metal stamping machine. Stamping may be used to form the concave molds 20 because stamping dies are considerably less expensive than mechanical tooling used in other processes such as, for example, molding, forging and casting dies, and expendable cutting tools. Moreover, quality, accuracy, function, wear life and appearance can all be dramatically improved by stamping. However, after forming the concave molds 20 into the panel 12 by stamping, the panel 12 may retain a shape memory imparted to the panel by peripheral metal stress from stamping pressure, as is shown generally in
To relieve any residual internal stresses in the hygienic baking pan 10 caused by forming the metal material 18, the panel 12 may be annealed to remove the shape memory. During the annealing process, the microstructure of the metal material 18 is altered, causing changes in its properties such as strength and hardness. Specifically, annealing is a process that produces equilibrium conditions by heating and maintaining at a suitable temperature, and then cooling very slowly. Annealing is often used to induce softness, relieve internal stresses, refine the structure and improve cold working properties.
For example, the panel 12 may be annealed to relieve internal stresses and allow the panel 12 to lay flat on a horizontal surface, as is shown in
After annealing, and to provide the hygienic baking pan 10 with increased rigidity, the sides 14, 15 and edges 16, 17 of the panel 12 may be folded with a bending brake to form a single fold 32 or a double fold 30, as is shown by
While providing a double fold 30 on both sides 14, 15 and both edges 16, 17 of the hygienic baking pan 10 may be beneficial for purposes of added rigidity, including a double fold 30 on both sides 14, 15 and both edges 16, 17 may be difficult if there is not enough excess metal material 18 to fold on the sides 14, 15 or edges 16, 17 of the panel 12 as can been seen, for example, at the edges 16, 17 of
Where there is not enough metal material 18 to fold into a double fold 30, the metal material 18 may be folded with a single fold 32, as is shown on the edges 16, 17 of the panel 12 in
In addition to the double and single folds, 30 and 32, respectively, a frame 22 may be provided as a source of additional support and to provide a desired rigidity to the hygienic baking pan 10. In an embodiment, the frame 22 comprises three support bars 24, 26, 28 that can be seen from a view of the bottom surface 12b of the panel 12 and as shown in
The support bars 24, 26, 28 may be made from the same metal material 18 as the panel 12 and as discussed herein above. In an embodiment, however, the support bars 24, 26, 28 are made from stainless steel. Moreover, the support bars may have a substantially rectangular shape, T-shape, I-shape, or any other shape desired so long as the support bars deliver the desired rigidity to the hygienic baking pan 10.
In an embodiment, the frame 22 may define exposed surfaces. The exposed surfaces may be fully accessible to a user and so constructed and arranged as to not define any points of accumulation as discussed herein above. In this embodiment, the full exposure of the exposed surfaces of the frame 22, except for junctions where the frame 22 is joined to the panel 12, allows a user to physically remove any build-up of a food product that might occur during use of the hygienic baking pan 10.
The frame 22 may be connected to the single fold 32 of the panel 12 and the portion of the double fold 30 that extends horizontally from the second fold 30b, as shown by
In
In an embodiment, and as shown in
In an embodiment, the gap 34 formed between the end of the support bar 26 and a vertical portion of the double fold 30 may extend for a majority of a junction between the panel 12 and the double fold 30 of the frame 22. The support bar 26 is joined to the double fold 30 where the support bar 26 and the portion of the double fold 30 that extends horizontally from the second fold 30b meet in a horizontal plane parallel to the top surface 12a of the panel 12, as is shown in
The support bars 24, 26, 28 may be joined to portions of the panel 12 by any joining means known in the art including, but not limited to, welding, soldering, and brazing. In an embodiment brazing, or braze welding, is used to join the support bars 24, 26, 28 to portions of the panel 12. Braze welding generally takes place at the melting temperature of the filler (e.g., 1600° F. to 1800° F. or 870° C. to 980° C. for bronze alloys) which is often considerably lower than the melting point of the base material (e.g., 2900° F. or 1600° C. for mild steel).
In an embodiment, a support bar 26 may be joined to the bottom surface 12b of the panel 12 by a hardened brazing paste 36, as is shown in
Another aspect of the present disclosure is to provide methods for manufacturing an apparatus for preparing a plurality of individual food products. For example, in an embodiment, a method for manufacturing an apparatus for preparing food products is provided. The method comprises manufacturing a single continuous sheet of metal material to form a tray having a top surface and two sides, forming the metal material sheet to form a plurality of concave molds therein, and joining a frame to the metal material sheet, wherein a gap is formed between the frame and the metal material sheet. In an embodiment, the frame is joined to the metal material sheet using a brazing paste.
In another embodiment, the method for manufacturing an apparatus for preparing food products further comprises annealing the metal material sheet. As discussed previously, the added step of annealing provides relief to internal stresses of a stamped metal material sheet thereby allowing the metal material sheet to lay flat on a horizontal surface. In an embodiment, the metal material may be formed by stamping.
The method for manufacturing an apparatus for preparing food products may further comprise folding the metal material sheet, as described hereinabove, to provide a desired degree of rigidity to the apparatus. For example, in an embodiment, the metal material sheet sides may be provided with a double fold. Similarly, in an embodiment, two metal material sheet edges may be provided with a single fold.
It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.
