Method for manufacturing a bakery cutting device

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cookie and cake cutters and, more particularly, to a method for manufacturing a cutter from a deformable metal strip into any desired configuration.
2. Background of the Prior Art
Cookie cutters have long been utilized to cut shapes from dough to provide cookies of different shapes for eating enjoyment during holidays or special occasions throughout the year. These cutters are usually simple in design and small in size because of the method of construction. The prior art method of constructing cutters is to shape the cutters by hand using rudimentary tools and molds. Prior art methods were the only means to maintain fabrication costs low enough to allow the cutters to be sold at a reasonable retail price. Although maintaining reasonable fabrication costs, prior art methods of manufacturing cookie cutters are not capable of providing low cost elaborate configurations at sizes corresponding to those of a box cake.
SUMMARY OF THE INVENTION
It is an object of the present invention to overcome many of the disadvantages associated with the methods of manufacturing a bakery cutting device. Other objects are to provide a method for manufacturing a bakery cutting device from a deformable metal strip; to provide a method for manufacturing a relatively large bakery cutting device having any desired configuration; to provide a method for manufacturing a bakery cutting device economically; and to provide a method for manufacturing a bakery cutting device for cutting cakes and cookies.
The present invention provides a method for manufacturing a bakery cutting device comprising the steps of selecting a configuration; dimensioning said configuration; selecting a deformable metal strip; configuring a plurality of dies to deform pre-selected portions of said metal strip into said selected configuration; securing together opposing ends of said metal strip, thereby deforming said metal strip into said selected configuration; and attaching handle means to said metal strip.

BRIEF DESCRIPTION OF DRAWINGS
These and other objects, advantages and novel features of the present invention, as well as details of an illustrative embodiment thereof, will be more fully understood from the following detailed description and attached drawings, wherein:
FIG. 1 is a perspective view of a bakery cutter configured as a clown in accordance with this invention.
FIG. 2 is a top elevation view of a bakery cutter configured as a clown in accordance with this invention.
FIG. 2A is a top elevation view showing the bend sections corresponding to the die drawings, infra.
FIG. 3 is a front elevation view of a bakery cutter configured as a clown in accordance with this invention.
FIG. 4 is a side elevation view of a bakery cutter configured as a clown in accordance with this invention.
FIG. 5 is a perspective view of a bakery cutter configured as a snowman in accordance with this invention.
FIG. 6 is a top elevation view showing the bend sections corresponding to cutter forming dies.
FIG. 7 is a front elevation view of a bakery cutter configured as a snowman in accordance with this invention.
FIG. 8 is a side elevation view of a bakery cutter configured as a snowman in accordance with this invention.
FIG. 9 is a perspective view of cutter forming dies that form Section 1 of FIG. 2A together with a metal strip extending therefrom.
FIG. 9A is a perspective view of cutter forming dies that form Section 1 of FIG. 2A apart, with an non-deformed metal strip inserted therebetween.
FIG. 10 is a top elevation view of cutter forming dies that form Section 1 of FIG. 2A.
FIG. 11 is a front elevation view of cutter forming dies that form Section 1 of FIG. 2A.
FIG. 12 is a side elevation view of cutter forming dies that form Section 1 of FIG. 2.
FIG. 13 is a perspective view of cutter forming dies that form Section 2 of FIG. 2A, together with a deformed metal strip extending therefrom.
FIG. 14 is a top elevation view of cutter forming dies that form Section 2 of FIG. 2A.
FIG. 15 is a front elevation view of cutter forming dies that form Section 2 of FIG. 2A.
FIG. 16 is a side elevation view of cutter forming dies that form Section 2 of FIG. 2A.
FIG. 17 is a perspective view of cutter forming dies that form Section 3 of FIG. 2A, together with a deformed metal strip extending therefrom.
FIG. 18 is a top elevation view of cutter forming dies that form Section 3 of FIG. 2A.
FIG. 19 is a front elevation view of cutter forming dies that form Section 3 of FIG. 2A.
FIG. 20 is a side elevation view of cutter forming dies that form Section 3 of FIG. 2A.
FIG. 21 is a perspective view of cutter forming dies that form Section 4 of FIG. 2A, together with a deformed metal strip extending therefrom.
FIG. 22 is a top elevation view of cutter forming dies that form Section 4 of FIG. 2A.
FIG. 23 is a front elevation view of cutter forming dies that form Section 4 of FIG. 2A.
FIG. 24 is a side elevation view of cutter forming dies that form Section 4 of FIG. 2A.
FIG. 25 is a perspective view of cutter forming dies that form Section 5 of FIG. 2A, together with a deformed metal strip extending therefrom.
FIG. 26 is a top elevation view of cutter forming dies that form Section 5 of FIG. 2A.
FIG. 27 is a front elevation view of cutter forming dies that form Section 5 of FIG. 2A.
FIG. 28 is a side elevation view of cutter forming dies that form Section 5 of FIG. 2A.
FIG. 29 is a perspective view of cutter forming dies that form Section 6 of FIG. 2A, together with a deformed metal strip extending therefrom.
FIG. 30 is a top elevation view of cutter forming dies that form Section 6 of FIG. 2A.
FIG. 31 is a front elevation view of cutter forming dies that form Section 6 of Section 2A.
FIG. 32 is a side elevation view of cutter forming dies that form Section 6 of FIG. 2A.
FIG. 33 is a perspective view of cutter forming dies that form Section 7 of FIG. 2A, together with a deformed metal strip in a clown configuration extending therefrom.
FIG. 34 is a top elevation view of cutter forming dies that form Section 7 of FIG. 2A.
FIG. 35 is a front elevation view of cutter forming dies that form Section 7 of FIG. 2A.
FIG. 36 is a side elevation view of cutter forming dies that form Section 7 of FIG. 2A.
FIG. 37 is a perspective view of forming dies having a straight metal strip therebetween illustrating an alternative method of manufacturing a bakery cutting device in accordance with this invention.
FIG. 38 is a perspective view of the forming dies of FIG. 37 pressed together with the metal strip correspondingly deformed therebetween in accordance with this invention.
FIG. 39 is a perspective view of forming dies having a metal strip partially deformed and partially straight therebetween illustrating an alternative method of manufacturing a bakery cutting device in accordance with this invention.
FIG. 40 is a perspective view of the forming dies of FIG. 39 pressed together with the metal strip correspondingly deformed therebetween in accordance with this invention.
FIG. 41 is a top elevation view of the forming dies and metal strip shown in FIG. 39.
FIG. 42 is a top elevation view of the forming dies and metal strip shown in FIG. 40.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 through 4, a bakery cutting device configured as a clown in accordance with this invention is denoted by numeral 10. The device or "cutter" 10 includes a metal strip 12, handle 14, and punch lock recess 16.
The metal strip 12 and handle 14 are fabricated from deformable, non-resilient, mill finished aluminum flat sheet having an alloy and temper identification number of 3003H14. The strip 12 and handle 14 total approximately forty-eight (48) inches in length. Both the strip 12 and handle 14 are one and one-half (11/2) inches in width and forty-thousandths (0.040) of an inch in thickness.
The metal strip 12 and handle 14 may be fabricated from other materials such as copper and stainless steel. Some commercial bakers use stainless steel, some retail outlets require copper cutters because copper provides a more artistic cutter. The respective thickness of each metal will vary due to the greater rigidity of these metals as compared to aluminum. Also, one may vary the aforementioned aluminum specifications depending on the desired rigidity and the intended use of the cutter. Although intended to cut cakes and cookies, the cutter could be utilized to cut jello, bread, ice cream, chocolate and other food products capable of being cut into a pre-determined configuration. Thus, the harder the food product the more rigid the strip 12 to cut the food product. Utilizing a thicker aluminum strip or a stiffer aluminum alloy, one could then cut a harder food product. However, the trade-off would be a more expensive cutter.
The strip 12 is deformed into a pre-selected configuration utilizing a method to be discussed, infra. After completing the configuration of the strip 12, first and second ends 18 and 20 are joined together to complete the configuration such that portions of first and second planar side walls 22 and 24 are in parallel contact, and first and second edge 26 and 28 form parallel planar rims, thereby allowing the cutter 10 to pass completely through a food product until contacting flush with an underlying support surface.
The handle 14 is joined to the strip 12 by bending first and second end portions 30 and 32 of the handle 14 at right angles to the first side wall 34 of the handle 14, and securing the end portions 30 and 32 to a portion of the first side wall 22 of the strip 12. The positioning of the handle 14 on the strip 12 should allow uniform pressure to be applied to the cutter 10 when pushing on the handle 14, thereby forcing the strip 1 through a baked box cake or other food product. Further, the distance between the first side wall 34 of the handle 14 and the second edge 28 of the strip 12 should be approximately two and one-half (21/2) inches. This dimension provides enough space between one's fingers when grasping the handle 14 and the top of a cake or other food product to be cut while maintaining enough rigidity in the handle 14 to prevent the handle 14 from collapsing under the pressure impressed upon the handle 14 when pressing the cutter 10 through the food product.
The joining of the strip end portions 18 and 20, and the handle 14 to the strip 12 is accomplished by using a mechanical punch lock machine similar to BTM Corporation Fastening Pres, Serial No. 014-85. The punch lock strikes the selected surfaces held adjacent to each other and creates recess 16, thereby forming a force fit between selected surfaces strong enough to hold the surfaces together when pressing the cutter 10 through a food product. Other securing means could be utilized such as rivets or screws, but these items would increase labor costs to assemble the cutter 10 as well as providing a sharp edge for one to cut themself upon.
Referring to FIGS. 1 through 8, perspective and elevation views of cutter 10, configured in the shape of a clown and snowman, are depicted. The method or process to manufacture the cutter 10 is to first draw a detailed picture of the configuration or character chosen. The picture is then scanned and downloaded into a computer and displayed on a computer screen. A rectangular box having dimensions of thirteen (13) inches in length and nine (9) inches in width is superimposed upon the screen containing the selected configuration therein. A scanning software similar to that provided by Logitech Corporation is utilized to stretch or shrink the configuration, in this use, a clown or snowman, until it is entirely within the perimeter of the box. The rectangular box represents the most popular size of cake pan (13".times.9") which would be utilized to bake the cake that the cutter 10 would configure. The computer then prints a full scaled picture which will then be used to construct a series of dies that deform the strip 12 into the desired configuration.
The dies utilized to configure the aluminum strip 12 are fabricated from a hard wood such as red oak, or a plastic block. Steel or other metals could be used, but the cost to shape metal dies would be prohibitively expensive, whereas using wood or plastic allows the cutter 10 to be economically manufactured. The wooden or plastic dies are approximately seven (7) inches square when viewed from the top and two (2) inches thick when viewed from the front or side. The dies are cut to conform to pre-selected portions of the picture printed by a computer as detailed above. The pre-selected portions are chosen by allowing only one (1) severe angle of bend to occur when pressing the aluminum strip 12 between any two dies which will be more apparent when reviewing the configuration of a clown cutter 10 infra.
Two dies are required to deform each pre-selected portion of strip 12. The present invention secures one die to a metal plate 35 (see FIG. 9) approximately nine (9) inches square and one-half (1/2) inch thick, via mounting bolt 37 which extend through die 36 and into threaded orifices in the plate 35. The plate 35 is then secured to a hydraulic work station where a hydraulic cylinder and shaft are utilized to force non-stationary die 38 against stationary die 36 with aluminum strip 12 therebetween. The strip 12 is positioned such that the second edge 28 is in parallel contact with the planar surface of the plate 35 and first and second side walls 22 and 24 are perpendicular to the planar surface of the plate 35. The hydraulic pressure required to force the dies 36 and 38 together with the strip 12 therebetween is approximately four thousand (4,000) pounds. The equipment required to generate this amount of force is well known to a person of ordinary skill in dealing with hydraulics. After being pressed between the dies, the aluminum strip 12 is permanently deformed to the contoured configuration of the pressing walls of the dies.
Referring to FIG. 2A, a top elevation view of a clown cutter 10 having seven (7) sections corresponding to seven (7) sets of dies that shape the clown cutter 10 is depicted. The number one (1) Section of the clown cutter 10 is formed by the dies 36 and 38 depicted in FIGS. 9 through 12. Referring to FIG. 9A, dies 36 and 38 are separated with strip 12 inserted therebetween. One should note that an extension portion 40 of strip 12 extends beyond first side walls 42 and 44 of dies 36 and 38. This extension is required because the aluminum strip 12 is drawn inward between the dies 36 and 38 from each portion of strip 12 extending beyond first side walls 42 and 44, and opposite second side walls 43 and 45 of dies 36 and 38.
After the dies 36 and 38 are completely pressed together (see FIGS. 9 and 9A), the extension portion 40 of aluminum strip 12 will be flush with the first side walls 42 and 44. The exact length of the extension portion 40 must be estimated initially, then adjusted in length with a new unbent strip 12 by trial and error until becoming flush with the first side walls 42 and 44 after pressing the dies 36 and 38 together. When the dies 36 and 38 are drawn apart, the strip 12 will remain deformed as depicted in the first section of FIG. 2A.
Referring to FIGS. 13 through 16, perspective and elevation views of the dies 46, 48 and 50 utilized to form Section 2 (see FIG. 2A) of the clown cutter 10 are depicted with strip 12 included in FIG. 13. One should note that there are three (3) dies that form Section 2 as compared to the two (2) dies 36 and 38 required to form Section 1. Dies 46 and 48 establish a positioning slot 52 used to prevent previously deformed Section 1 from being drawn between dies 46 and 50 when the dies are pressed together to form Section 2 of clown cutter 10.
The positioning slot 52 receives a restraining portion 53 of Section 1 of strip 12. A straight portion 54 of strip 12 protrudes longitudinally beyond side wall 55 of die 46. One must physically bend the straight portion 54 in the direction of arrow 56 while keeping the second edge 28 of strip 12 in the same plane with lower planar surface 58 of die 46 until the strip 12 contacts the pressing wall 60 of die 46. Die 50 is then pressed against die 46, thereby forming Section 2 of clown cutter 10.
The sizes of the positioning slot 52 and the corresponding restraining portion 53 required to prevent the deformed Section 1 portion from being drawn between dies 46 and 50 is dependent upon the angle formed when bending the straight portion 54 against the pressing wall 60 of die 46. The greater the angle of bend, the greater the friction between the strip 12 and the die 46 at a starting point 62 on die 46 that begins the formation of Section 2 of the strip 12. The greater the friction between the strip 12 and starting point 62, the smaller the positioning slot 52 required to prevent deformed Section 1 from being drawn between dies 46 and 50. Through trial and error, it has been determined that positioning slot 52 needs to be approximately two and one-half (21/2) inches in length to restrain Section 1 of strip 12.
Referring to FIGS. 17 through 20, perspective and elevation views of dies 64, 66 and 68 utilized to form Section 3 (see FIG. 2A) of the clown cutter 20 are depicted with strip 12 included in FIG. 17. Again, there are three (3) dies required to form Section 3. Dies 64 and 66 establish positioning slot 70 required to prevent previously deformed Section 2 from being drawn between dies 64 and 68 when pressed together to form Section 3 of clown cutter 10.
The positioning slot 70 receives restraining portion 72 of Section 2 of strip 12. A straight portion 74 of strip 12 protrudes longitudinally beyond side wall 76 of die 64. Straight portion 74 does not need to be physically bent in this Section. Die 68 is then pressed against die 64, thereby forming Section 3 of clown cutter 10. The size of the positioning slot required to restrain Section 2 of strip 12 is approximately three (3) inches.
Referring to FIGS. 21 through 24, perspective and elevation views of dies 78, 80 and 82 utilized to form Section 4 (see FIG. 2A) of the clown cutter 10 are depicted with strip 12 included in the perspective view. Dies 78 and 80 establish positioning slot 84 required to prevent previously deformed Section 3 from being drawn between dies 78 and 82 when pressed together to form Section 4 of clown cutter 10.
The positioning slot 84 receives restraining portion 86 of Section 3 of strip 12. A straight portion 88 of strip 12 protrudes longitudinally beyond side wall 92 of die 78. Straight portion 88 must be physically bent in the direction of arrow 90 while keeping the second edge 28 of strip 12 in the same plane with lower planar surface 94 of die 78 until the strip 12 contacts the pressing wall 96 of die 78. Die 82 is then pressed against die 78, thereby forming Section 4 of clown cutter 20. The size of the positioning slot 84 required to restrain Section 3 of strip 12 is approximately four and one-half (41/2) inches.
Referring to FIGS. 25 through 28, perspective and elevation views of dies 98, 100 and 102 utilized to form Section 5 (see FIG. 2A) of the clown cutter 10 are depicted with strip 12 included in the perspective view. Dies 98 and 100 establish positioning slot 104 required to prevent previously deformed Section 4 from being drawn between dies 98 and 102 when pressed together to form Section 5 of the clown cutter 10.
The positioning slot 104 receives restraining portion 106 of Section 4 of strip 12. A straight portion 108 of strip 12 protrudes longitudinally beyond side wall 110 of die 98. Straight portion 208 must be bent in the direction of arrow 112 while keeping second edge 28 of strip 12 in the same plane with lower planar surface 114 of die 98 until the strip 12 contacts the pressing wall 116 of die 98. Die 102 is then pressed against die 98, thereby forming Section 5 of clown cutter 10. The size of positioning slot 104 required to restrain Section 4 of strip 12 is approximately three 3 inches.
Referring to FIGS. 29 through 32, perspective and elevation views of dies 118, 120 and 122 utilized to form Section 6 (see FIG. 2A) of the clown cutter 10 are depicted with strip 12 included in the perspective view. Dies 118 and 120 establish positioning slot 124 required to prevent previously deformed Section 5 from being drawn between dies 118 and 122 when pressed together to form Section 6 of clown cutter 10.
The positioning slot 124 receives restraining portion 126 of Section 5 of strip 12. A straight portion 128 of strip 12 protrudes longitudinally beyond side wall 130 of die 118. Straight portion 128 must be bent in the direction of arrow 132 while keeping second edge 28 of strip 12 in the same plane with lower planar surface 134 of die 118 until the strip 12 contacts the pressing wall 136 of die 118. Die 122 is then pressed against die 118, thereby forming Section 6 of clown cutter 10. The size of positioning slot 124 required to restrain Section 5 of strip 12 is approximately three and one-half (31/2) inches.
Referring to FIGS. 33 through 36, perspective and elevation views of dies 138, 140 and 142 utilized to form Section 7 (see FIG. 2A) of the clown cutter 10 are depicted with strip 12 included in the perspective view dies 138 and 140 establish positioning slot 144 required to prevent previously deformed Section 6 from being drawn between dies 138 and 122 when pressed together to form Section 7 of clown cutter 10.
The positioning slot 144 receives restraining portion 146 of Section 6 of strip 12. A straight portion 148 of strip 12 protrudes longitudinally beyond side wall 150 of die 138. Straight portion 148 must be bent in the direction of arrow 152 while keeping second edge 28 of strip 12 in the same plane with lower planar surface 154 of die 138 until the strip 12 contacts the pressing wall 156 of die 138. Die 142 is then pressed against die 138, thereby forming Section 7 of clown cutter 10. The size of positioning slot 144 required to restrain Section 6 of strip 12 is approximately four (4) inches.
Securing the end portions of the strip 12 and the handle 14 to the strip 12, as discussed supra, are the only remaining steps to the fabrication of the clown cutter 10. Using the same teachings and principles of fabrication discussed herein, any required configuration or character can be manufactured.
Referring now to FIGS. 37-42, perspective and top elevation views of dies having a metal strip therebetween illustrate an alternative method for manufacturing a bakery cutting device in accordance with this invention. FIG. 37 shows the first step in configuring the metal strip 202. Similar to the prior method, the first bend utilizes the draw from first and second end portions 204 and 206 of the strip 202. The strip 202 is positioned between first and second dies 208 and 210 such that a predetermined length of first end portion 204 extends beyond the perimeter of the dies 208 and 210. The predetermined length is determined through trial and error to minimize the length of the first end portion 204 extending beyond the perimeter of the first and second dies 208 and 210 after the first die 208 is pressed against the anchored second die 210. To allow for faster configuration of the metal strip 202, a third die or stopping block 212 is mounted to allow the first end portion 204 of the metal strip 202 to "butt-up" against the block 212 thereby eliminating the actual measuring of the first end portion 204 that extends beyond the dies perimeter.
Materials and fabrication techniques for securing dies to metal plate as detailed in the first manufacturing method, supra, are incorporated herein. Further, hydraulic equipment and pressures required to force dies together in this alternative manufacturing method are the same as mentioned above.
Referring now to FIG. 38, dies 208 and 210 are shown pressed together with strip 202 deformed therebetween. First end portion 204 extends only slightly beyond the perimeter of dies 208 and 210. This slight extension will not have any consequence to the formation of the bakery cutting device.
Referring now to FIGS. 39 and 41, perspective and top elevation views show partially deformed strip 202 inserted between first, second and third dies 214, 216 and 218. The positioning of the strips 202 between the dies 214, 216 and 218 is similar to the first method utilized for configuring the second bend of a metal strip; however, in this alternative method of deforming the strip 202, positioning slot 220 defined by mounted dies 216 and 218 is substantially "wider" than the "narrow" positioning slots utilized in the first method of manufacturing detailed, supra.
The function of the "narrow" positioning slot is to secure the deformed portion of the metal strip during the configuring process of the adjacent straight section of the metal strip. Thus, a positioning slot is dimensioned to snugly receive the metal strip thereby forcing the draw upon the metal strip to occur on only the straight portion when the corresponding dies are pressed together.
The function of the "wider" positioning slot is to allow the metal strip to be drawn from both ends. Referring again to FIG. 39 and 41, the metal strip 202 is positioned in communication with die 218. In essence, die 218 is a "stopping block" for the first deformed portion 222 of the metal strip 202. When the first die 214 is pressed adjacent to the second die 216 (see FIGS. 40 and 42) a second portion 224 of the metal strip 202 is configured correspondingly to the contours of the first and second dies 214 and 216. The draw upon the strip 202, during the configuration of the second portion 224 of the strip 202, occurs from the remaining straight portion 226 and the already configured first portion 222.
This alternate method of manufacture can be utilized for any design and for many dies and configurations as may be required. The advantage of alternative method or "wide slot" method over the aforementioned or "narrow slot" method is that having a wide slot and backdrawing the metal strip 202 from each end portion provides faster fabrication of the cutting configuration along with less binding when the configured metal strip 202 is removed from the die assembly. Thus, the time required to form the metal strip 202 in to a predetermined figure is reduced significantly.
The disadvantage of the "wide slot" method as compared to the "narrow slot" method is that the trial and error technique utilized to determine the backdraw for all configurations pressed into the metal strip 202 and the corresponding separation between adjacent dies forming the "wide slot" after the first configuration portion 222 is pressed, results in a relatively large amount of waste that is directly related to the complexity and contour depth of the die design.
Although the preferred embodiment of the invention is that of a bakery cutting device, utilizing either of the two aforementioned methods of manufacturing to fabricate a bakery mold device of any predetermined design, is also within the scope of this invention. Obviously, a handle is not required when fabricating a mold. Further, a mold could be used as a cutting device provided that sufficient force can be exerted upon the mold to cut through cookie dough or a cake without damaging the mold. Fabricating a mold in a cutting device without a handle simplifies the method of manufacturing by deleting the relatively labor intensive step of forming and attaching a handle to a predetermined portion of the configured metal strip 202.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings., Thus, it is to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described above.

Number	Name	Date	Kind
190018	Erzinger	Apr 1877
922926	Lynch	May 1909

Method for manufacturing a bakery cutting device

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