Abstract:
A roll forming apparatus having a shaft member for supporting a head member above a baking container housing a dough mass. The head member can include a plurality of arms with corresponding guide blades disposed therein for contacting a peripheral wall of the container. A tension assembly is mounted about the shaft member for adjusting movement and an outward force of each of the guide blades. Upon insertion in a baking pan, the head member&#39;s arms and guide blades divide the dough into a plurality of dough lobes without damaging the container. In a roll forming process, a rack is provided for receiving and transporting the roll forming apparatus over the container. A securing assembly is mountable about the shaft member for permitting the shaft member to resiliently pivot toward a generally perpendicular orientation with respect to the rack after the container pivotally displaces the head member.

Description:
REFERENCE TO RELATED APPLICATIONS 
   This application claims the benefit of priority under 35 U.S.C. § 119(e)(1) of a provisional patent application Ser. No. 60/549,044, filed Mar. 1, 2004, which is incorporated herein by reference in its entirety. 

   FIELD OF THE INVENTION 
   The invention relates to roll forming devices, particularly roll forming devices adapted to form a roll having a plurality of lobes interconnected by a web of dough. 
   BACKGROUND OF THE INVENTION 
   Bread and dinner roll forming devices, particularly roll forming devices adapted to form a roll having a plurality of lobes have been used. The roll forming devices or stampers typically have a shaft supporting a head or a roll forming body that presses into a ball or mass of dough placed in a baking pan. The roll forming body typically has retractable arms, each of which are coupled to the roll forming body by an internal horizontally oriented spring. Each of the internal springs biases the arms outward and prevents each arm from being removed from the roll forming body for purposes of routine cleanings. As a result, the movement of each of the retractable arms becomes restricted over time due to clogging caused by dough accumulation, thereby reducing the life of the roll forming body. Health concerns can also arise when the roll forming body cannot be properly cleaned due to the fixed nature of each of the retractable arms within the roll forming body. 
   Since the internal springs constantly exert a fixed outward force upon each of the retractable arms that engage the inner surface of the baking pan, such constant force can eventually damage the baking pans and the protective coatings on the inner surface. Moreover, any misalignments between the roll forming body and the baking pans can either cause substantial damage to the pan or may require the baking production to be slowed to align the pan with the roll forming body. As a result, the baking pans can deteriorate more quickly and throughput can be substantially reduced, thereby increasing the overall cost of producing the rolls. 
   SUMMARY OF THE INVENTION 
   In order to minimize health risks and production costs, while increasing productivity, it is desirable that the outwardly directing force of each of the guide blades be adjustable to limit the amount of damage to the inner surface of the baking pans. Moreover, it is also desirable to configure guide blades that are easier and faster to clean. 
   The roll forming apparatus, according to the various embodiments of the invention includes a shaft member for supporting a head member above a baking container or baking pan containing a unit of dough. The head member includes arms with corresponding guide blades disposed therein for contacting a peripheral wall of the baking container. A tension assembly is mounted about the shaft for adjusting movement of the guide blades between extended and retracted position. Upon insertion into the baking pan, the head member&#39;s arms and guide blades divide the unit of dough into a plurality of dough lobes, interconnected by a web of dough, without damaging the baking pan. In a related embodiment of the invention, the roll forming apparatus is resiliently pivotal to a generally perpendicular orientation with respect to a rack or supporting plate that supports the roll forming apparatus above the baking container. 
   The above summary of the various embodiments of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. The figures in the detailed description that follow more particularly exemplify these embodiments. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which: 
       FIG. 1  is perspective view of a roll forming head member, shaft and tension arrangement of an embodiment of the invention. 
       FIG. 2  is a top end plan view of the shaft and tension arrangement. 
       FIG. 3  is a bottom end plan view of the roll forming head with arms and guide blades. 
       FIG. 4  is a side view of the roll forming head member, shaft and tension arrangement. 
       FIG. 5  is another side view of the roll forming head member, shaft and tension arrangement. 
       FIG. 6  is another side view of the roll forming head member, shaft and tension arrangement illustrating one of the guide blades in a retracted position. 
       FIG. 7  is side view of a plurality of roll forming apparatus coupled to a rack. 
       FIG. 8  is a top plan view of the roll forming system illustrating a plurality of the roll forming apparatus inserted into a baking container. 
       FIG. 9  is a partial cutaway side view illustrating a head member of the roll forming apparatus disposed in a baking container. 
       FIG. 10  is a side view of a portion of the roll forming system illustrating adjustment by the roll forming device when the rack is misaligned with the baking container. 
       FIG. 11  is a partial cutaway side view of a guide blade extending out of an interior of the head member for cleaning. 
   

   While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. 
   DETAILED DESCRIPTION 
   In an embodiment of the invention, a roll forming apparatus or device is provided, as shown generally at  10  in  FIG. 1 , the device being capable of forming a multi-lobed roll from a unit of dough. In an example embodiment, the roll forming apparatus of the invention comprises a head member disposed on a shaft member for supporting the head member above a baking container having a bottom wall and at least one peripheral wall. The head member has a plurality of outwardly radiating arms and a plurality of guide blades. Each of the guide blades is disposed in an interior of a respective arm and cantilevers between an extended position and a retracted position. A tension assembly is also included for adjusting the resistance of the guide blades from moving from the extended position toward the retracted position. In another embodiment, a securing assembly is mountable about the shaft member for pivotally securing the shaft member to a rack or a supporting plate above a baking pan. 
     FIG. 1  provides a perspective view of a roll forming apparatus  10  with a head member  20  disposed on a shaft member  12 . Head member  20  divides the unit of dough or dough mass into a plurality of dough lobes interconnected by a web of dough. In this embodiment, head member  20  has a proximal end  21  and a distal end  22 . As illustrated in  FIGS. 4–6 , a plurality of arms  24  extend generally from proximal end  21  toward distal end  22  divides the unit of dough in the baking container into the dough lobes of a multi-lobed or multi-leaf roll. Referring again to  FIG. 1 , distal end  22  is blunt such that when head member  20  is pressed into the baking container, the dough is pressed generally downward forming the web of dough that interconnects the bottom surfaces of each of the dough lobes. The thickness of the web of dough varies depending upon the depth of insertion of head member  20  into the baking container. 
   Referring to  FIG. 3 , in this embodiment each of the arms  24  has a free end  25  extending between proximal  21  and distal  22  ends. Free end  25  of each of the arms  24  has an opening  26  extending into an interior  27  therein. As particularly illustrated in FIGS.  1  and  4 – 6 , each of the plurality of arms  24  has a length that tapers from proximal end  21  toward distal end  22 . The tapering of each of the plurality of arms  24  permits head member  20  to be insertable into baking containers having sloping peripheral walls and for inserting into baking containers with varying interior diameters.  FIG. 3  illustrates a plurality of guide blades  30  disposed in interior  27  of head member  20 . Each of guide blades  30  is adapted for independently contacting an inner surface of the peripheral wall of the baking container. 
   In the embodiment illustrated in  FIGS. 5–6 , each of guide blades  30  has first  32  and second  34  opposed edges and a free edge  36  extending therebetween. Referring to  FIG. 6 , first  32  and second  34  opposed edges may be generally rounded and free edge  36  may be generally blunt. However, free edge  36  may also be generally rounded such that it has an outer surface that permits it to make generally full contact with an inner surface of the peripheral wall of the baking container. 
   In one embodiment, each of guide blades  30  is independently positionable between an extended and a retracted position with respect to head member  20 . The extended position is characterized by free edge  36  of each of the guide blades  30  being generally non-parallel to free end  25  of each of the arms  24  for purposes of cleaning head member  20 . The retracted position is characterized by free edge  36  of each of the guide blades  30  becoming more generally parallel to free end  25  of each of the plurality of arms  24  after head member  20  is inserted into the baking container. In the retracted position, free edge  36  exerts an outward force. 
   In an embodiment of the invention, as illustrated in  FIG. 4 , a pin  28  pivotally couples each of guide blades  30  in a corresponding interior  27  of the plurality of arms  24  to permit guide blades  30  to cantilever between the extended (untensioned) and retracted (tensioned) positions. Pin  28  is positioned generally adjacent distal end  21  and free end  25  of the plurality of arms  24 . 
     FIGS. 4–6  provide side views of a device according to an embodiment of the invention, illustrating shaft member  12  having first  13  and second  14  opposed ends with second end  14  of shaft member  12  coupled to head member  20 . An outer surface of shaft member  12  can be threaded as shown, to permit threaded engagement of tension assembly  40 . Alternatively, an entire length of the outer surface of shaft member  12  may be threaded. As illustrated in  FIG. 6 , second end  14  of shaft member  12  is threadedly disposed in a threaded bore extending into proximal end  21  of head member  20  to permit removal of shaft member  12  for cleaning. Shaft member  12  can comprise a substantially rigid material such as steel or aluminum. One skilled in the art would appreciate that other materials may be utilized. 
   Tension assembly  40  is removably mountable about shaft member  12  for adjusting a resistance of movement of each of the guide blades  30  from the extended position toward the retracted position.  FIG. 6  illustrates tension assembly  40  having a plate member  41  and a biasing member  43  to bias plate member  41  to retractably engage first edge  32  of each of the guide blades  30 . Plate member  41  is positioned generally adjacent to proximal end  21  of head member  20 . As illustrated in  FIG. 6 , first edges  32  of guide blades  30  extend generally above proximal end  21  of head member  20 . 
   In one embodiment, before head member  20  is inserted into a baking container, biasing member  43  and plate member  41  generally maintains guide blades  30  in the extended positions. Referring to  FIGS. 6 and 11 , plate member  41  is generally retractable toward first end  13  of shaft member  12  to permit a substantial portion of each of guide blades  30  to freely cantilever out of interior  27  and away from head member  20  for thorough cleaning of arms  24  and guide blades  20 . 
   In another embodiment, as illustrated in  FIG. 6 , tension assembly  40  can include a collar  42  that is threaded about shaft member  12 . Collar  42  is positioned on shaft member  12  such that biasing member  43  is disposed generally between collar  42  and plate member  41 . In this embodiment, rotation of collar  42  clockwise compresses biasing member  43  against plate member  41 , thereby increasing the resistance of movement of guide blades  30  from the extended position toward the retracted position as head member  20  is inserted into the baking container and each of guide blades  30  contacts the peripheral wall of the baking container. Likewise, counterclockwise rotation of collar  42  reduces the resistance of guide blades  30  moving from the extended position toward the retracted position. Depending upon the baking container being used, guide blades  30  resistances can be adjusted to prolong the life of the baking container. Collar  42  is a threaded nut and biasing member  43  is a helical spring. However, one skilled in the art would appreciate that other types of fasteners and biasing members may be utilized to regulate the resistance of movement of guide blades  30  from the extended position toward the retracted position. 
   As illustrated in  FIGS. 4–11 , a securing assembly  50  is mountable about shaft member  12  to removably secure shaft member  12  to a rack  60  (or supporting plate) that carries shaft member  12  and head member  20  to the baking container. As illustrated in  FIGS. 6 and 7 , securing assembly  50  may include first  51  and second  52  coaxially opposed securing members and a compression member  54  coaxially disposed on shaft member  12  and positioned generally therebetween. As illustrated in  FIGS. 7 and 9 , shaft member  12  and head member  20  are resiliently pivotal to a generally perpendicular orientation with respect to rack  60 . 
     FIG. 8  provides a top plan view of rack  60  supporting shaft member  12  and a plurality of head members  20  above a baking container  70 . Head members  20  and baking container  70  are shown in an aligned position in registration with an interior of the baking container. This embodiment also shows an arrangement of head members  20  with respect to rack  60 . The arrangement and number of head members  20  can vary depending upon the number of rolls being formed. This arrangement can be part of a manual or automatic roll forming system. 
   As illustrated in  FIG. 9 , rack  60  can raise and lower head members  20  into the interior of container  70 , such as in the directions shown by Arrow A. In this embodiment, first end  13  of shaft member  12  is disposable into a hole  61  of rack  60  having a diameter generally larger than a diameter of shaft member  12  but generally smaller than an outer diameter of securing members  51  and  52 . Rack  60  is generally positioned between first securing member  51  and an end of compression member or spring  54 . Second securing member  52  is threadedly adjustable about shaft member  12  and operably abuttable compression member  54 . In this embodiment, counterclockwise rotation of second securing member  52  compresses compression member  54  and sandwiches rack  60  between first securing member  51  and compression member  54 . 
   Referring to  FIG. 10 , pivotal movement of shaft member  12  in hole  61  of rack  60  permits head member  20  to pivot in a manner that it is free to enter baking container  70  that is generally out of alignment with head member  20 . Compression member  54  generally acts to permit shaft member  12  and head member  20  to resiliently pivot to a generally perpendicular orientation with respect to rack  60  after being removed from a baking container unaligned with head member  20 . Rotation of first  51  and second  52  securing members adjusts the resistance of shaft member  12  to pivot between a generally perpendicular orientation and a generally non-perpendicular orientation with respect to rack  60 . As particularly illustrated in  FIG. 10 , shaft member  12  can freely pivot in hole  61  such as in direction of Arrow B. 
   Referring back to  FIGS. 4 and 6 , collar  42  and first  51  and second  52  securing members each have a split  56  extending therein forming a pair of opposed ends  57  and  58 . A fastener  66  extends into and operably couples opposed ends  57  and  58  of collar  42  and first  51  and second  52  securing members. In one embodiment, rotation of fasteners  66  loosens or tightens collar  42  and first  51  and second  52  securing members with respect to shaft member  12 . Fasteners  56  may comprise a hex nut or any other conventional fastener known to one skilled in the art. 
   In operation, a baking container may be carried along a process line via a conveyor belt assembly to various operations such as roll forming, baking and packaging. During a roll forming operation, rack  60  lowers head member  20  into baking container  70 , as illustrated in  FIGS. 8–10 . Guide blades  30  contact the inner surface of the peripheral wall of the baking container. As head member  20  extends into the baking container, the peripheral wall of the baking container causes guide blades  30  to cantilever from the extended position toward the retracted position. Head member  20  with arms  24  and guide blades  30  compress dough downward into the baking pan and form the web of dough. Rack  60  can then be lifted away from the baking container withdrawing head member  20 . When head member  20  is extracted from the baking container, tension assembly  40  can cause guide blades  30  to cantilever outwardly from the retracted position toward the extended position. 
   Rotation of collar  42  about shaft member  12  can increase or decrease the resistance of each of the guide blades  30  to cantilever from the extended position toward the retracted position. Once a desired level of resistance is obtained, fastener  66  sets collar  42  in position. Adjusting movement of resistance of guide blades  30  permits a user to set the amount of contact between guide blades  30  and the peripheral wall of the baking container. The length of time a baking container can be used is extendable by adjustment of tension assembly  40 . 
   In a baking operation, a plurality of baking containers may be connected to form a baking container unit. A unit of dough can be placed into each of the baking containers of the baking container unit by any number of processes. Rack  60  may have a plurality of holes  61  arranged in rows corresponding to a generally similar arrangement of the baking containers in the baking container unit. A plurality of roll forming devices  10  is securable to rack  60  in a manner as described above. Rack  60 , as described in this operation, may be movable along the baking process line to a plurality of baking container units at various points along the processing line. As a result, a substantial increase in roll formation output is obtained. 
   Roll formation output can be increased by a reduction in the number of interruptions of roll formation processing. As the plurality of baking container units is conveyed on the conveyor belt, it is not uncommon for some of them to move slightly from their original positions. This is also possible in a manual system of baking. As a result, a baking container unit may become misaligned with the operational positioning of rack  60 . However, the ability of each of the roll forming devices  10  to pivot with respect to rack  60  permits head members  20  to enter the baking containers of the baking container unit and form the rolls from the measured units of dough. Additionally, when rack  60  is raised, head members  20  from the misaligned baking container unit each of the roll forming devices  10  can be returned to a generally perpendicular orientation with respect to rack  60  for proper insertion into the next baking container. 
   The invention may be embodied in other specific forms without departing from the essential attributes thereof; therefore, the illustrated embodiments should be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.