Abstract:
A laterally standardized hollowed out potato has an opening through a wall of potato communicating with an interior cavity, with a filling within the cavity. When the potato is resting on one of its relatively broader sides, the opening faces upwardly, so that a liquidy filling is reliably contained. The laterally standardized nature of the potato facilitates mass production, as well as a consistent sidewall thickness.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]    This is a continuation-in-part of Ser. No. 09/306,259, filed May 6, 1999, the entire disclosure of which is hereby expressly incorporated by reference. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    This invention relates generally to pre-prepared food products and, more particularly, to a stuffed baked potato frozen food product and to methods for making the product.  
           [0003]    Easy-to-prepare packaged frozen food items have become important commercial products, appealing to persons who desire to prepare tasty and nutritious meals at home in a minimum amount of time. Particularly when cooking in relatively small quantities, such as for one or two people, it is inefficient and time consuming to assemble and prepare multiple ingredients that are a characteristic of appetizing and healthy meals.  
           [0004]    Potatoes are well recognized as a nutritious food, having a taste and texture which compliments the other ingredients of a complete meal. A variety of snack food products also are made of potatoes.  
           [0005]    Hollowed-out and stuffed potato food products have previously been proposed. However, there remains a need for a stuffed potato food product which can readily be mass-produced and which can reliably be re-heated by a consumer, for example in a microwave oven, without suffering a leak or a blow-out.  
         SUMMARY OF THE INVENTION  
         [0006]    In an exemplary embodiment of the invention, a stuffed potato food product includes a laterally standardized hollowed-out potato having a wall of potato material. The potato has two ends, with a longitudinal axis extending between the two ends. The potato has a pair of opposed relatively broader sides generally parallel to each other and to the longitudinal axis. Each of the relatively broader sides generally defines a respective plane of stability. In other words, when placed on a horizontal surface, the potato is stable when either one of the relatively broader sides is contacting the horizontal surface. Finally, the potato has a pair of opposed relatively narrower sides generally parallel to the longitudinal axis. The potato is trimmed to a standardized oval or flat-oval shape in plan view, so as to define a standardized periphery with vertical walls perpendicular to one of the planes of stability defined by one of the relatively broader sides. There is an opening through the wall in the other of the relatively broader sides communicating with an interior cavity having a cross-sectional extent larger than the opening. Finally, there is a filling within the cavity.  
           [0007]    A corresponding method of preparing a stuffed potato food product begins with providing a potato having two ends with a longitudinal axis extending between the two ends, a pair of opposed relatively broader sides generally parallel to each other and to the longitudinal axis, each of the relatively broader sides generally defining a respective plane of stability, and a pair of opposed relatively narrower sides generally parallel to the longitudinal axis. A cutter is employed to trim the potato to a standardized oval or flat-oval shape in plan view so as to define a standardized periphery, with vertical walls perpendicular to one of the planes of stability being defined by one of the relatively broader sides, thereby producing a laterally standardized potato A rotating potato-hollowing bit is employed to hollow out the standardized potato, leaving a wall of potato material, an opening through the wall in the other one of the relatively broader sides, and an interior cavity having a cross-sectional extent larger than the opening. A filling is introduced into the cavity through the opening.  
           [0008]    The stuffed potato food product may be frozen as part of a manufacturing process, and may be later thawed and cooked, for example, in a microwave oven. Since the opening faces upwardly, a liquidy filling may reliably be contained. Embodiments of the invention make it feasible to mass produce stuffed potato food products. Thus the laterally standardized potato facilitates positive registration with reference to the potato-hollowing bit. This allows automated, volumetrically measured filling. In addition, the resultant constant sidewall thickness promotes a consistent degree of doneness during cooking, avoiding undercooked or overcooked spots. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]    While the novel features of the invention are set forth with particularly in the appended claims, the invention, both as to organization and content, will be better understood and appreciated, from the following detailed description taken in conjunction with the drawings, in which:  
         [0010]    [0010]FIG. 1 is a top or plan view of a graded potato, such as a Russet or Burbank potato;  
         [0011]    [0011]FIG. 2 is an end elevational view of the graded potato, taken on line  2 - 2  of FIG. 1;  
         [0012]    [0012]FIG. 3 depicts the use of a cutter to trim the graded potato to a standardized oval or flat-oval shape;  
         [0013]    [0013]FIG. 4 depicts the resultant laterally standardized potato in top or plan view;  
         [0014]    [0014]FIG. 5 is a side elevational view of the laterally standardized potato, taken on line  5 - 5  of FIG. 4;  
         [0015]    [0015]FIG. 6 is an end elevational view of the laterally standardized potato, taken on line  6 - 6  of FIG. 4;  
         [0016]    [0016]FIG. 7 is a side elevational view of a generalized machine for hollowing out laterally standardized potatoes carried on a conveyer;  
         [0017]    [0017]FIG. 8 is a plan view taken on line  8 - 8  of FIG. 7, depicting a single laterally standardized potato in a carrier;  
         [0018]    [0018]FIG. 9 depicts a rotary cutting tool, with its blades retracted;  
         [0019]    [0019]FIG. 10 depicts the FIG. 9 rotary cutting tool with the blades extended;  
         [0020]    [0020]FIG. 11 shows internal portions of the cutting tool in isolation, with the blades extended;  
         [0021]    [0021]FIG. 12 is a side elevational view, partially broken away, depicting the cutting of a slot in a laterally standardized potato;  
         [0022]    [0022]FIG. 13 is a view similar to FIG. 12, depicting a subsequent step, wherein the cutting tool is employed to hollow out a cavity;  
         [0023]    [0023]FIG. 14 is a top or plan view of a hollowed-out potato;  
         [0024]    [0024]FIG. 15 depicts a filling operation;  
         [0025]    [0025]FIG. 16 is a side cross-sectional view of a finished product; and  
         [0026]    [0026]FIG. 17 is a top view thereof, taken on line  17 - 17  of FIG. 16. 
     
    
     DETAILED DESCRIPTION  
       [0027]    [0027]FIG. 1, is a top or plan view and FIG. 2 is an end elevational view of a graded potato  20 , such as a Russet or Burbank potato. The potato is graded so as to be part of a batch of potatoes which are generally similar in size, but not identical. The potato  20  has two ends  22  and  24 , and, for purposes of description, a longitudinal axis  26  extending between the two ends  22  and  24 . The potato  20  has a pair of opposed relatively broader sides  28  and  30  which are generally parallel to each other and to the longitudinal axis  26 . Each of the relatively broader sides  28  and  30  defines a respective plan of stability. In other words, when placed on a horizontal surface, the graded potato  20  is stable when either one of the relatively broader sides  28  or  30  is contacting the horizontal surface.  
         [0028]    The potato  20  also has a pair of relatively narrower sides  32  and  34 , which are also generally parallel to the longitudinal axis. Typically, a potato  20  is not stable when one of its relatively narrower sides  32  and  34  is contacting a horizontal surface. As is perhaps best seen in FIG. 2, the relatively broader sides  28  and  30  are not necessarily wider than the relatively narrower sides  32  and  34 . However, in a typical potato  20 , what are herein termed the relatively narrower sides  32  and  34  are more rounded than the relatively broader sides  28  and  30 , which accordingly are somewhat flatter.  
         [0029]    Referring next to FIG. 3, which is a top or plan view in the same orientation as FIG. 1, a cutter generally designated  40 , having a cutting blade  42  and a mount  44 , is employed to trim the potato  20  to a standardized oval or flat-oval shape. The cutter  40  employs the same principle as a cookie cutter, but is appropriately sized to accommodate a potato. The trimming of the potato  20  is done in an automatic machine (not shown).  
         [0030]    [0030]FIGS. 4, 5 and  6  show a resultant laterally standardized potato  50 . The laterally standardized potato  50  has a standardized oval or flat-oval shape in plan view (FIG. 4), with a standardized periphery  52 . The laterally standardized potato  50  has vertical walls  54 ,  56 ,  58  and  60  which are perpendicular to one of the planes of stability defined by the relatively broader sides  28  and  30 , in the illustrated embodiment, perpendicular to the bottom side  28 .  
         [0031]    Referring next to FIG. 7, represented is a machine  70  for hollowing out laterally standardized potatoes  50 . The machine  70  includes a conveyer  72  driven by a stepper drive motor  74 , which is capable of driving the conveyer  72  in either a forward or reverse direction, in incremental steps as required. Mounted to the conveyer  72  in a suitable manner are a plurality of representative potato carriers  76 ,  78  and  80 . Although omitted for purposes of illustration, it will be appreciated that there are other potato carriers (not shown), including on the underside of the conveyer  72 . Likewise, a mechanism for introducing laterally standardized potatoes into the potato carriers  76 ,  78  and  80 , for example, on the left side of the conveyer  72 , is not shown, nor a mechanism for removing laterally standardized and hollowed-out potatoes from the carriers  76 ,  78  and  80 , for example to the right side of the conveyer  72 .  
         [0032]    [0032]FIG. 8 is a plan view depicting the manner in which a laterally standardized potato  50  is held within a mating cavity  82  within the potato carrier  74 . Thus, the laterally standardized potato  50  is positively registered and located with reference to the machine  70 .  
         [0033]    Referring again to FIG. 7, a rotating cutting tool assembly  90 , which also may be referred to as a potato-hollowing bit assembly  90 , described in greater detail hereinbelow with reference to FIGS.  9 - 13 , is connected to a cutter drive mechanism  92  which both rotates the cutting tool assembly  90 , as indicated by rotational arrow  94  and moves the cutting tool assembly  90  up and down, as indicated by arrow  96 . In addition, the cutter drive mechanism  92  controls the extension and retraction of blades within the cutting tool assembly  90 , as is described herein below with reference to FIGS.  9 - 13 .  
         [0034]    In addition, the cutting tool assembly  90  incorporates conduits for introducing water, such as a water spray into a potato as it is being hollowed out, as well as section conduits, so that pieces of potato material being removed are continually flushed away. Thus, a water supply designated  98  and a suction device  100  are connected to the cutter drive mechanism  92  and thus to the potato-hollowing bit assembly  90 .  
         [0035]    It will be appreciated that relative movement between the laterally standardized potatoes  50  on the conveyer  70  and with reference to the potato-hollowing bit assembly  90  is effected by coordinated movements of the conveyer  72  driven by the stepper drive motor  74  and the cutter drive mechanism  92 . A suitable controller  102  is connected to the stepper drive motor  74  and to the cutter drive mechanism  92  to effect the required movements, as is described in greater detail hereinbelow with reference to FIGS. 12 and 13.  
         [0036]    With reference now to FIGS. 9, 10 and  11 , the rotating potato-hollowing bit assembly  90  is depicted in greater detail. The bit assembly  90  includes an outer tubular conduit  110 , and a set  112  of retractable cutting blades  114 ,  116  and  118 , connected to an internal cutting blade carrier  120 . During operation, when the internal cutting blade carrier  120  is drawn all the way up, as depicted in FIG. 9, the cutting blades  114 ,  116  and  118  are fully retracted. As depicted in FIG. 10, when the cutting blade carrier  120  is moved downwardly with reference to the outer tubular conduit, the cutting blades  114 ,  116  and  118  spread apart. At an intermediate position (depicted herein below with reference to FIG. 12), the cutting blades  114 ,  116  and  118 , protrude only partially from the end of the outer tubular conduit  110 , resulting in a relatively smaller diameter cutting pattern. The cutting blades  114 ,  116  and  118  are hinged to a hub  122  which moves vertically along a shaft  124  with reference to a stop  126 , and which is urged downwardly by a compression spring  128 . The linkage is such that when the hub  122  moves downwardly with reference to the stop  126  under the urging of the spring  128 , the cutting blades  114 ,  116  and  118  spread apart to cut a relatively larger diameter cutting pattern.  
         [0037]    [0037]FIG. 12 depicts a step, carried out by the machine  70  of FIG. 7, of initially cutting a slot  140 , which eventually becomes a slotted opening  140 . In FIG. 12, the cutting blades  114 ,  116  and  118  are just slightly extended, to produce a relatively narrow slot, only slightly wider than the diameter of the rotating potato-hollowing bit assembly  90 . Several passes may be required to form the slotted opening  140 , accomplished by cooperative movements between the conveyer  70  and the rotating potato-hollowing bit assembly, under direction of the controller  102 .  
         [0038]    Referring next to FIG. 13, when the slotted opening  140  has been fully formed, the rotating potato-hollowing bit assembly  90  is driven deeper into the laterally standardized potato  50 , and the cutting blades  114 ,  116  and  118  extended fully, so as to form a cavity  142  having a cross-sectional extent larger than the slotted opening  140 .  
         [0039]    [0039]FIG. 14 is a plan view of the result, showing the slotted opening  140 , and the extent of the cavity  142  indicated by dash lines. The sidewall thickness is typically ½ to ⅝ inch, and relatively constant. Thus, during cooking, this relatively uniform sidewall thickness results in a consistent degree of doneness, with no undercooked or overcooked spots.  
         [0040]    [0040]FIG. 15 depicts a subsequent operation by which a filling  150  is introduced into the cavity  140 , through a suitable nozzle  152 . Filling  152  is semi-liquid, or any other suitable consistency, with or without solid chunks such as meat sufficiently small to pass through the opening  140 . A wide variety of fillings  150  may be employed, depending upon the particular product being made. For a complete entree or meal in a potato, chunks of steak and mushroom in a wine sauce may be employed.  
         [0041]    With reference to FIGS. 16 and 17, after the filling  150  is introduced into the cavity  142 , a closure, generally designated  154 , is introduced into the unfilled space. The closure  154  more particularly comprises a closing mixture which sufficiently solidifies upon subsequent baking, or partially baking.  
         [0042]    As subsequent steps (not shown), prior to consumer packaging, the entire product is coated with a suitable mixture so as to entirely conceal the nature of the vertical walls  54 ,  56 ,  58  and  60 .  
         [0043]    Embodiments of the invention accordingly make it feasible to mass produce stuffed potato food products because bulk, inexpensive potatoes may be employed, mechanically cut and shaped to a standardized oval or flat-oval shape. This trimming or shaping eliminates the need for hand-sorted potatoes, which are prohibitively expensive. Thus, each potato is in register with respect to the cavity  140  created by the rotating potato-hollowing bit assembly  90 . Significantly, the wall thickness is relatively constant, resulting in more uniform baking characteristics.  
         [0044]    Since the movement of the cutting tool and/for the conveyer are repetitive and pre-programmed, each slotted opening  140  and cavity  142  are identical from potato to potato. This allows for automated, volumetrically measured filling.  
         [0045]    Having the entry slot on the relatively broader side  30  of the potato allows the potato to rest naturally without leaking. Thus, gravity keeps the filling in place during cooking. The closure  154  is not strictly necessary, and may be added after the potato product is frozen during manufacture.  
         [0046]    While specific embodiments of the invention have been illustrated and described herein, it is realized that numerous modifications and changes will occur to those skilled in the art. It is therefore to be understood that the appended claims are intended to cover all such modifications and changes that fall within the true spirit and scope of the invention.