Abstract:
A device for simultaneously and evenly toasting articles of differing contours and dimensions arranged upon a heated griddle. A clamshell plate, positioned in stand-off relationship above said griddle-arranged articles, has a plurality of slideably moveable fingers or pins mounted therein which float, that is, are brought into contacting and resting relation with the upper surfaces of said articles to provide a gentle pressure thereon to urge the lower surfaces into more intimate contact with the griddle until the toasting process is completed, thereby accelerating the toasting process without undesirable side effects such as distortion of, and condensation on, the upper surfaces and caramelization of the lower surfaces of said articles.

Description:
CROSS-REFERENCE TO RELATED INVENTIONS 
     Continuation-in-part of Ser. No. 60/323,470, filed Sep. 18, 2001, the contents of which are incorporated by reference. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable 
     MICROFICHE APPENDIX 
     Not Applicable 
     BACKGROUND OF THE INVENTION 
     This invention relates to an improved toasting apparatus, particularly suited for use in a fastfood restaurant operation for the toasting of buns. In the 1950′s most buns were toasted by placing them face down on a flat griddle. They absorbed the heat radiated off the griddle surface, and were toasted in about four to six minutes. Subsequent decades brought mechanized bun toasters of two basic types. The first is radiant toasters (e.g., home toasters) which utilize heat elements that never directly touch the bun, but toast through radiant heat transfer. Modern commercial radiant toasters utilize a conveyor belt to allow quicker processing of buns. A second type of toaster is the contact toaster, which uses a conveyor to run a bun over a hot surface. These toasters use an opposing surface to compress the bun and get good contact of the lower surface of the bun with the hot surface. 
     While both radiant and contact toasters allow quicker and easier toasting, they do not impart the same quality of toast as the old fashioned method of placing buns on a flat griddle. Quality oriented fast-food restaurants continue to use the old fashioned toasting method because of the flavor and texture it imparts to the bun. However, most contact toasters use pressure to accelerate the toasting process, typically, by using an opposing plate to compress the bun. The disadvantages of this method include distortion of the shape of the bun by compressing it at its highest points, and allowing condensation to form on the top surface of the bun, which changes texture. 
     The prior art discloses contact toasters wherein weights are placed upon the bun surface opposite the surface placed upon a griddle to be toasted. Relevant prior art includes U.S. Pat. No. 2,225,068, Bun Toasting Machine, issued Dec. 17, 19940, and U.S. Pat. No. 3,126,813, Self-Adjusting Weights for Toasting Machine, issued Mar. 31, 1964. 
     Each of these references discloses weights arranged on conveyor chains which move buns forward along a toasting plate. In U.S. Pat. No. &#39;068, FIGS. 4 and 5, the weights are seen to be discs said to be ⅔ the diameter of the bun, the curvature of the plurality of discs conforming “approximately to the average curvature of the top of the bun”. U.S. Pat. No. &#39;813 discloses chain-suspended weights which are self-adjusting to the extent of accommodating themselves to articles of variable size, shape or thickness as articles are conveyed across a toasting plate. The weights are formed in roughly a “U” shape with a flat bottom of approximately four square inches between an upwardly curved front wall and an upwardly extending rear wall, with a central cut-out portion so as to be formed with side suspension arms having apertures to receive a hinge shaft transversely connected to the conveyor chains. When then the weight is hanging freely from the hinge shaft, the bottom wall is positioned in a substantially horizontal plane. 
     The weights described in the references are for use with conveyor contact toaster systems. In each of the patents, the weights are such that the bun is conformed to the shape of the weight. Sliding the bun surface across the toasting griddle tends to promote caramelization. Caramelization is defined as the process of changing the sugar content of a food into caramel, an amorphous brittle brown and somewhat bitter substance, by heating sugar, thereby changing bun texture as well as taste. Further, the large contact surface of the weights disclosed present a relatively large surface area thus being susceptible to condensation which wets the upper surface of the bun and changes the texture thereof. Further, for a given “footprint,” the space necessarily dedicated to the conveyor mechanism leaves much less working space. 
     It is, therefore, an object of the present invention to provide improved weighted means which can exert downward pressure on articles being toasted, and which are self-adjusting to the extent of accommodating themselves to contours and dimensions of articles of said various sizes, shapes or thickness. 
     It is another object of this invention to provides a means of simultaneously and uniformly toasting articles of differing contours and dimensions without distortion of the upper surface contour thereof, while avoiding the caramelization of the article surface contacting the griddle; 
     It is a further object of the present invention to provide a maneuverable and compact apparatus having a minimum “footprint” for use at cooking stations where space is limited. 
     And yet another object is to provide improved weights for a clamshell griddle toaster which will float upon and exert downward pressure on the upper surface of articles being toasted, which will be self-adjusting to the extent of accommodation to articles of varying dimensions and contours as placed upon the griddle, and which will present a minimal surface area for collection of condensation as an incident of the toasting operation. 
     BRIEF SUMMARY OF THE INVENTION 
     the present invention relates to a method and apparatus for simultaneously and evenly toasting articles of differing shapes and sizes on a flat metal surface griddle. By way of example, a hamburger bun is sliced horizontally through its midsection, the top potion hereinafter being identified as the “crown,” and the lower portion as the “heel.” The apparatus comprises a hinged clamshell plate perforated with a multitude of passageways, into each of which is slideably arranged an improved weighted finger or pin, which plate can be lowered over a griddle surface to a position whereby each finger, moving independently, floats, i.e., rests upon, and places a gentle pressure upon the upper surface of the articles arranged upon the griddle, such as bun crowns and heels, irrespective of their differing contours. 
     It is a feature of the present invention that, in operation, the clamshell plate containing the improved weighted fingers from a generally vertical disengaged position travels downwardly, in an arcuate clockwise path, transitioning to a generally horizontal orientation parallel to the plane of the griddle, whereupon the plate continues its decent in a vertical path to a stand-off position above the griddle. The small, weighted fingers are lowered gradually from the clamshell plate and rest on the bun surface. Each finger moves independently and places a small weight on the bun portions. The sum of many fingers provides a gentle pressure on the bun upper surfaces which accelerates the toasting process without distorting the shape thereof and, because of the configuration of the bun-touching finger ends, a minimal area is presented for the collection of condensation. Thus, improvement of toasting speed and quality are achieved without the negatives of other toasting methods. When the toasting process is completed, the clamshell lid is raised, and the bun portions can be removed. New bun portions are then added to the griddle and the process is repeated. It has been found that the Floating Clamshell Bun Toaster speeds up the toasting process by 40 to 50% while imparting the same flavor and texture as the old fashioned flat griddle toasting technique. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     FIG. 1 is a perspective view of the griddle toaster of the present invention; 
     FIG. 2 is an exploded view assembly drawing of the clamshell plate and associated mechanism; 
     FIG. 3A is a front view of the improved pin; 
     FIG. 3B is a top view of a pin; 
     FIG. 3C is a pictorial view of a pin, showing the formed end and the flattened end; 
     FIG. 4 is a partial to view of the clamshell plate with improved pins positioned therein; 
     FIG. 5 is a partial front view of the clamshell plate, taken along section line  5 — 5  of FIG. 4, showing pins positioned upon bun crowns and heels; 
     FIG. 6 illustrates the clamshell plate at its lowest and horizontal position; 
     FIG. 7 shows the clamshell plate in a substantially horizontal position as it begins its vertical upward ascent; 
     FIG. 8 illustrates the clamshell plate in its counter-clockwise upward travel; 
     FIG. 9 shows the clamshell plate in its substantially vertical position; 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to FIG. 1, the present invention relates to a toaster apparatus  10  for simultaneously and evenly toasting articles of differing shapes and sizes, such as sliced portions of a hamburger bun, on a heated flat metal surface, i.e., griddle  12 , more particularly to toast the inside surfaces of a cut hamburger bun in an even manner in as short a time as possible. As shown in FIG. 5, to aid in this process, means are provided for applying gentle pressure to the top surfaces of the bun crown  26  and heel  28  to ensure that the crown and heel undersides are in intimate contact with the griddle surface  12 . The apparatus  10  comprises a hinged clamshell plate  14  perforated with a multitude of passageways  16 , into each of which are slideably arranged improved pins  18 , said clamshell plate  14  adapted to being raised above or lowered to a stand-off position in proximity to the heated griddle surface  12  whereby each pin  18 , moving independently floats, that is, rests and places a gentle pressure upon the upper surface of articles arranged upon the griddle, irrespective of the article&#39;s contour. 
     The toaster  10  has a plate or griddle  12  upon which crowns  26  and heels  28  of the sliced bun are placed to be toasted. The griddle plate  12  is manufactured from a high strength aluminum alloy which is hard-anodized to give the cooking surface  12  superior wear characteristics and excellent heat-transfer capacity. The toaster is heated by electric heater plates (not shown) and enclosed with stainless steel covers and a “belly guard” to prevent accidental contact with the griddle plate  12 . 
     Referring to FIG. 2, the pin plate  14  is manufactured from acetal homopolymer material, noted for low friction, low moisture absorption and dimensional stability. A series of passageways  16  in a regular pattern with one inch spacing are drilled through the plate  14 . Into these holes are inserted the fingers  18  in the form of pins, manufactured from 5052 Aluminum alloy with a clear anodize finish for corrosion resistance. The design of the pin, best shown in FIGS. 3A,  3 B, and  3 C features multiple radii at the formed end  20 , so the pins do not mark the buns during initial contact or withdrawal. FIG. 4 shows the positioning of the pins  18  within the passageway  16  of the plate  14 , with the formed rounded ends  20  extending downwardly. The other ends of the pins  22  are flattened to two different heights  22   a ,  22   b , shown in FIG. 5, to allow for the different thickness between the top and bottom halves of the buns  26 ,  28 . The pins  18  are thus free to move up and down in their respective passageway  16  as they come into contact with the upper surfaces of the buns, applying pressure without damaging the delicate baked surface. In the preferred embodiment, four hundred eighty six (486) pins  18  were deployed within a plate surface area  14  of approximately two hundred eighty four (284) square inches, a ratio of 1.7 plus pins per square inch. While the ratio of number of pins per unit of plate area may vary, the useful range varies from one (1) pin per square inch (for large buns) to three (3) pins per square inch for smaller buns. 
     As further illustrated in FIG. 2, two handles  30 ,  31  are furnished to facilitate attachment and removal of the pin plate  14  for cleaning. The pin plate  14  is mounted into a frame assembly  32 , reinforced by a supporting angle  34 , which is constrained by four arms arranged in pairs evenly about the centerline of the frame  32 . The lever arms  42 ,  43  guide the lower side of the frame  32  and also provide a counter balancing force through two torsion springs  48   a ,  48   b  associated with spring collars  49 . A tubular connector  45 , held in place with setscrews  41  to ensure equal movement of both arms in unison, joins the lever arms  42 ,  43 . The connecting arms  46 ,  47  guide the top of the frame  32 . The lever and connecting arms  42 ,  43 ,  46 ,  47  are connected to the frame assembly  32  by shoulder bolts  55  passing through bushings  51 , secured by locking pins  57 , capped by dome nuts  56  and are attached to a pair of support bracket  44   a ,  44   b  through bushings  52   a ,  52   b  and secured by shoulder bolts  53   a ,  53   b , said support brackets providing the lower pivot points  50   d.    
     The normal operation of the pin plate mechanism  40  is to rotate the pin plate  14  clockwise using the attached handle  30 . The initial rotation is rapid until the plate  14  is at approximately 45° to the horizontal when the speed of rotation decreases. When the plate reaches approximately two inches above a lower stop position, the movement becomes largely vertical. At a position approximately one inch from the lower stop position the formed ends  20  of the bun pins  18  float, i.e., make contact with and rest upon the upper surfaces of the bun halves  26 ,  28 , causing the bun pins  18  to slide upwardly through the bun plate  14 . As the plate continues to move towards its lowest horizontal position the weight of the bun pins  18  is brought fully to bear on the bun halves  26 ,  28  thereby pressing the lower surfaces fully against the grill surface  12  to ensure quick and even toasting. 
     Referring to FIGS.  2  and  6 - 9 , the geometry of the pin plate mechanism  40  is such that the length of the connecting arms  46 ,  47  is shorter than the length of the lever arms  42 ,  43 . Also, the position of the pivot points  50   a  for the connecting arms  46 ,  47  and the position of the pivot points  50   b  for the lever arms  42 ,  43  on the frame  32  are offset both horizontally and vertically. Similarly, the position of the pivot points  50   c  for the connecting arms  46 ,  47  and the position of the pivot points  50   d  for the lever arms  42 ,  43  on the support brackets  44   a ,  44   b  are offset both horizontally and vertically. This arrangement constrains the movement of the frame  32  and also the griddle plate  14  so that from the lowest position (FIG. 6) for the first two inches of upward movement the frame  32  and plate  14  remain largely horizontal (see FIG. 7 ). In the preferred embodiment, when the frame  32  and plate  14  reach a height of three inches they start to rotate anti-clockwise, as viewed in FIG.  8 . The anti-clockwise rotation continues slowly until such time as an imaginary line drawn through the centerline of the lever arm  42  passes above the support bracket connecting arm pivot  50   c . At this point, the speed of rotation increases considerably such as the final fifteen degrees of rotation of the lever arm generates forty-five degrees of rotation of the frame  32  and plate  14 . As shown in FIG.9, at the end of travel the frame  32  and plate  14  are in a substantially vertical position. Mechanical stops (not shown) are positioned to limit arc of travel to required positions. And, as illustrated in FIG.1 the pin plate mechanism  40  is mounted onto and above the griddle plate  12 . As seen in FIG. 2, a cover  54  is provided to protect the moving parts of the mechanism and screws  33  connect the handles  30 ,  31  and the supporting angle  34  to the frame  32 . The pin plate  14 , pin plate mechanism  40  and cover  54  are all removable for cleaning without the use of tools, a requirement for regulatory approval. 
     While the preferred embodiment of the invention has been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made thereto without departing from the spirit of the invention, the scope of which is defined by the appended claims.