Cooking appliance and method of cooking a packaged food product

An appliance cooks packaged food items, such as making pancakes, crepes, flapjacks and the like. There is a method of cooking the packaged food items.

CROSS-REFERENCE TO RELATED APPLICATIONS

See Application Data Sheet.

Not applicable.

THE NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT

Not applicable.

Not applicable.

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a cooking appliance, a method of cooking a packaged food product, a packaged food product and package for a food product.

The invention has been developed primarily for cooking batter based food products such as cakes, crepes, pancakes and waffles, or egg based products such as quiches, omelettes and cooked eggs, and will be described hereinafter with reference to these applications. However, it will be appreciated that the invention is not limited to this particular field of use.

Cooking batter based or egg based food products can often be messy, take a lot of time and require extensive cleaning. The present invention seeks to overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

BRIEF SUMMARY OF THE INVENTION

According to a first aspect, the present invention provides an appliance for cooking a food product, the appliance comprising:at least one cooking assembly comprising first and second heatable plates movable relative to each other between:an open configuration at which a food product can be placed between the first and second plates; anda closed configuration at which the first and second plates are moved towards a first relative distance to each other to contact respective opposing sides of the food product, wherein the first and/or second plates are movable to a greater second relative distance therebetween.

Preferably, the first and/or second plates are movable to at least one third relative distance therebetween, the at least one third relative distance being between the first and second distances.

Preferably, the at least one third relative distance comprises a predetermined minimum distance between the first and second plates.

In another aspect, the present invention provides an appliance for cooking a packaged food product, the appliance comprising:at least one cooking assembly comprising first and second heatable plates movable relative to each other between:an open configuration at which the packaged food product can be placed between the first and second plates; anda closed configuration at which the first and second plates are moved towards a first relative distance between the plates to contact respective opposing sides of the packaged food product, wherein gases produced within the package during the cooking process expands the package and moves the plates to a second larger distance therebetween, and release of the gases from the package allows the plates to move back closer to each other to a third relative distance between the first and second distances.

Preferably, the appliance comprises a plurality of the cooking assemblies. Preferably, each cooking assembly is individually actuatable.

Preferably, the first, second and/or the third relative distances are adjustable.

Preferably, the second relative distance can be limited to a predetermined maximum second distance.

Preferably, the plates are adapted to remain in contact with the food product up to the third relative distance.

Preferably, the plates are adapted to provide a compressive force to the food product up to the third relative distance.

In one embodiment, the plates are oriented generally vertically in the closed configuration.

In another embodiment, the plates are oriented generally horizontally in the closed configuration.

In another embodiment, the plates are oriented at an inclined angle in the closed configuration.

In one embodiment, the first and second plates are both movable between the open and closed configurations.

In another embodiment, the first plate remains substantially stationary and the second plate is movable relative to the first plate between the open and closed configurations.

Preferably, each cooking assembly is adapted to eject the food product from between the plates after a predetermined cooking time.

Preferably, the appliance comprises a base body and a lid body, wherein the first plate is mounted to the lid body and the second plate is mounted to the base body.

Preferably, the lid body is pivotable relative to the base body between an open configuration and a closed configuration.

Preferably, the base body comprises a bottom wall, side walls, a rear wall and a front wall which together define a lower internal space, wherein the second plate is disposed within the lower internal space.

Preferably, the lid body comprises a top wall, side wall, a rear wall and a front wall which together define an upper internal space, wherein the first plate is disposed within the upper internal space.

Preferably, the second plate comprises a heatable top surface which is recessed from a peripheral border.

Preferably, the second plate is pivotably mounted so as to be movable between a generally horizontal position and a tilted position.

Preferably, the appliance further comprises a tilting assembly operatively extending between the first and second plates, whereinwhen the first and second plates are in the closed configuration, the tilting assembly positions the second plate in its horizontal position,when the first and second plates are moved to the open configuration, the tilting assembly lifts a rear portion of the second plate to move the second plate to its tilted position; andwhen the first and second plates are moved to the closed configuration, the tilting assembly returns the second plate to its horizontal position.

Preferably, the first and second plates are resiliently biased to the open configuration.

Preferably, the appliance further comprises a stopper for retaining the plates in the closed configuration.

Preferably, the stopper is connected to a cooking timer which releases the first and second plates at the end of a cooking period.

Preferably, the first plate is mounted via a mounting mechanism for movement in a substantially perpendicular direction relative to the second plate in the closed configuration.

In one embodiment, the first plate is mounted to a lid body and the mounting mechanism comprises, on each side of the first plate, a pair of spaced parallel arms pivotably mounted to respective portions of the first plate and to respective portions of the lid body.

In another embodiment, the first plate is mounted to a lid body and the mounting mechanism comprises spaced posts mounted to the lid body and extending generally perpendicularly to first plate, the first plate comprising formations respectively engaging the posts to allow the first plate to be movable along the posts.

Preferably, the first and second plates are substantially parallel to each other in the closed configuration.

In another embodiment, the first and second plates are at an acute angle to each other in the closed configuration.

Preferably, the appliance further comprises a retaining assembly for providing a predetermined minimum distance between the first and second plates in the third relative distance therebetween.

Preferably, the retaining assembly comprises a pivotable retaining arm having a retaining leg biased to a position of engagement with the first plate.

Preferably, the retaining assembly comprises a release means for moving the retaining leg away from its engagement position when the first and second plates move to their closed configuration.

Preferably, the first and second plates have a maximum length and width of about 20 cm each.

Preferably, the first and second plates comprise a flat heatable surface.

In another embodiment, at least one of the first and second plates comprises a textured heatable surface.

In another aspect, the present invention provides a packaged food product comprising an outer package and a food product disposed within the package, wherein the package is heat resistant and allows the food product to be cooked via heated plate contact with the package.

Preferably, the package comprises first and second panels sealed to each other along their peripheral portions to form an internal chamber therewithin, the food product being disposed within the internal chamber.

In one embodiment, at least one of the first and second panels is stretchable or expandable.

Alternatively, the package comprises first and second spaced panels and at least one side wall connecting peripheral portions of the first and second panels to form an internal chamber therewithin, the food product being disposed within the internal chamber.

In one embodiment, the at least one side wall is stretchable or expandable.

In another embodiment, the at least one side wall comprises a concertina structure.

Preferably, the food product is at least one of a batter based food product for making a cake, a crepe, a pancake or a waffle, or an egg based product for making a quiche an omelette or cooked egg.

In another embodiment, at least one of the first and second panels is shaped to provide a contoured texture to the food product.

Preferably, during the cooking process, the package allows the food product to expand and/or produce gases within the internal chamber.

In one embodiment, the package minimises the release of the gases from the internal chamber.

In another embodiment, the package releases the gases from the internal chamber after a predetermined pressure within the internal chamber is reached.

Preferably, the predetermined pressure is about 1.5 bar.

Preferably, the package comprises release means for releasing the gases when the predetermined pressure is reached.

Preferably, the release means comprises at least one seal which opens at the predetermined pressure.

In another embodiment, the package is adapted to constantly release the gases from the internal chamber at a slow predetermined rate.

Preferably, the release means comprises at least one aperture of predetermined diameter formed in the package.

Preferably, the panels comprise peel tabs for peeling the panels from each other.

In another aspect, the present invention provides a method of cooking a packaged food product, the method comprising:disposing the packaged food product between first and second heatable plates in a first relative distance between the plates;allowing gases to be produced within the package during the cooking process which expands the package and moves the plates to a second relative distance therebetween; and allowing release of the gases from the package and allowing the plates to move back towards each other up to a minimum third relative distance therebetween.

In another aspect, the present invention provides a package for a food product, the package comprising first and second spaced panels connected at their peripheral portions to form an internal chamber therewithin, wherein the package is heat resistant and allows the food product to be cooked via heated plate contact with the package.

In another aspect, the present invention provides a package for a food product, the package comprising first and second spaced panels and at least one side wall connecting peripheral portions of the first and second panels to form an internal chamber therewithin, wherein the at least one side wall is stretchable or expandable.

In one embodiment, the at least one side wall comprises a concertina structure. Preferably, the internal chamber is fully sealed.

In another aspect, the present invention provides a package for a food product, the package comprising first and second panels joined to each other along their peripheral portions to form an internal chamber therewithin, wherein the first and second panels comprise non-stick material.

Preferably, the first and second panels comprise heat resistant, food approved material.

In another aspect, the invention may be said to consist in a packaged food arrangement comprisingan outer package comprising an upper layer of heat resistant polymer film, and a lower layer of heat resistant polymer film; anda food product disposed within the package, the food product comprising at least a binder and a raising agent;wherein the package food product is configured in a flat configuration.

In one embodiment, the packaged food product is configured in a flat configuration suitable for convenient cooking of the food product by heated plate contact on the upper layer and lower layer.

In one embodiment, the upper layer of heat resistant polymer film on the lower layer of heat resistant polymer film is composed of two separate sheets that are bonded to each other at least around their periphery.

In one embodiment, the package food arrangement is substantially planar.

In one embodiment, the packaged food arrangement defines an upper major face and a lower major face, and peripheral edges.

In one embodiment, the width of the packaged food arrangement between its major faces is between 0.5 millimetres and 50 mm.

In one embodiment, the width of the packages food arrangement between its major faces is between 2 mm and 20 mm.

In one embodiment, the width of the packaged food arrangement between its major faces is about 10 mm.

In one embodiment, the package comprises a first panel and a second panel sealed to each other along their periphery to form an internal chamber therewithin, the food product being disposed within the internal chamber.

In one embodiment, the upper layer of heat resistant polymer film and the lower layer of heat resistant polymer film is composed of a single sheet.

In one embodiment, wherein at least one of the first panel and second panel is one or more selected from stretchable and expandable.

In one embodiment, the package comprises first and second spaced panels and at least one side wall connecting peripheral portions of the first and second panels to form an internal chamber therewithin, the food product being disposed within the internal chamber.

In one embodiment, the at least one side wall is stretchable or expandable.

In one embodiment, the at least one side wall comprises one or more selected froma concertina formation,a pleat formation, anda telescoping formation.

In one embodiment, the food product comprises at least a binder and a raising agent.

In one embodiment, the food product comprises at least a binder, a sweetener, fat and a raising agent.

In one embodiment, the food product is at least one selected from a batter based food product for making a cake, a crepe, a pancake, a crumpet, a flapjack a waffle, or an egg based product for making a quiche, an omelette or cooked egg.

In one embodiment, at least one of the first and second panels is shaped to provide a contoured texture to the food product.

In one embodiment, during the cooking process, the package allows the food product to expand and/or produce gases within the internal chamber.

In one embodiment, the package is configured to minimise the release of the gases from the internal chamber.

In one embodiment, the package is configured to release the gases from the internal chamber after one or more selected from a predetermined pressure and a predetermined volume within the internal chamber is reached

In one embodiment, the predetermined pressure is about 1.5 bar.

In one embodiment, the package comprises release means for releasing the gases when said one or more selected from a predetermined pressure and a predetermined volume is reached.

In one embodiment, the release means comprises one or more selected from at least one seal and at least one perforation which opens at the predetermined pressure.

In one embodiment, the package is adapted to constantly release the gases from the internal chamber at a slow predetermined rate.

In one embodiment, the release means comprises at least one aperture of predetermined diameter formed in the package.

In one embodiment, the panels comprise peel tabs for peeling the panels from each other.

In one embodiment, the food product is freezable.

In one embodiment, the upper layer is one or more selected frombonded to the lower layer;heat sealed to the lower layer; andultrasonically bonded to the lower layer.

In another aspect, the invention may be said to consist in a method of cooking a packaged food product, the method comprising:disposing the packaged food product between a first heatable plate and a second heatable plate, with the first heatable plate and the second heatable plate being disposed at a first relative distance from each other;allowing gases to be produced within the package during the cooking process which expands the package and moves the plates to a second relative distance therebetween; andallowing release of the gases from the package and allowing the plates to move back towards each other up to a minimum third relative distance therebetween.

In another aspect, the invention may be said to consist in a packaged food arrangement, the package comprisinga first panel and a second panel; andat least one side wall connecting peripheral portions of the first panel and second panel to form an internal chamber therewithin,a food product located within the internal chamber, the food product comprising a binder and a raising agent;wherein the at least one side wall is stretchable or expandable.

In one embodiment, the at least one side wall comprises one or more selected from concertina formation, a pleat formation and a telescoping formation.

In another aspect, the invention may be said to consist in a packaged food arrangement, the package comprisinga first panel and a second panel; andat least one side wall connecting peripheral portions of the first panel and second panel to form an internal chamber therewithin,a food product located within the internal chamber, the food product comprising at least a binder and a raising agent;wherein the at least one side wall is stretchable or expandable.

In one embodiment, the at least one side wall comprises one or more selected froma concertina formation,a pleat formation anda telescoping formation.

Other aspects of the invention are also disclosed.

DETAILED DESCRIPTION OF THE INVENTION

Appliance

It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features.

FIGS. 1 to 9show a cooking appliance10in accordance with a preferred embodiment of the present invention. The cooking appliance10will be described with reference to cooking a packaged food product or packaged food arrangement. However, the cooking appliance10can also be used for cooking unpackaged food products.

Referring initially toFIGS. 1 to 6, the cooking appliance10comprises a base body20and a lid body30.

The base body20comprises a bottom wall21, side walls22, a rear wall23and a front wall24. The walls21to24together define a base internal space25and a peripheral base upper edge26of the base body20. A pivotable lower plate40is disposed within the base internal space25as further described below.

The lid body30is similarly formed as the base body20includes a top wall31, side wall32, rear wall33and a front wall34. The walls31to34also together define a lid internal space35and a peripheral lid lower edge36of the lid body30. A movable upper plate50is disposed within the lid internal space35as further described below.

The lid body30is pivotably mounted to the base body20via a hinge39extending along adjacent edge portions of the rear walls23and33. The lid body30is pivotable relative to the base body20between an open configuration and a closed consideration. Movement of the lid body30can be performed manually, at which the lid body30preferably includes a handle, or automatically via motor control.

In the open configuration, the lid body30is generally moved away from the base body20thus exposing the lower plate40and the upper plate50. In the closed configuration, the base upper edge26and the lid lower edge36abut each other, with the side walls22and32, rear walls33and23and front walls24and34aligned respectively. Thus, in the open configuration, the lower plate40and the upper plate50are disposed away from each other and a food item can be disposed or removed from therebetween, and in the closed configuration, the lower plate40and the upper plate50are adjacent each other for cooking the food item disposed therebetween.

The lower plate40comprises a body41with a generally planar heatable top surface42. The top surface42is slightly recessed from a peripheral border44by a distance of 3 to 10 mm. The lower plate40is pivotably attached at a front pivot portion46thereof to the side walls22.

Referring toFIGS. 7 to 9, a tilting assembly70extends between a rear portion of the lid body30and a rear portion47of the lower plate40. The tilting assembly70comprises a bent rigid arm72attached to the lid body30, a post73extending downwardly from the lower plate40, and a link74. The arm72comprises a first end75attached to the lid body30and a second distal end76. The link74is pivotably attached to the second end76and also pivotably attached to the post73.

When the lid body30is in the closed configuration (FIG. 7), the tilting assembly70positions the lower plate40at its horizontal position, at which the top surface42is substantially parallel and adjacent the base upper edge26. When the lid body30is pivoted from the closed configuration to the open configuration, the tilting assembly70lifts the rear portion47above the base upper edge26(FIG. 8), until the lower plate40reaches its tilted position (FIG. 9) where the top surface42is at a downward angle generally extending toward the front wall24. The lower plate40in this tilted position is presented for placing a packaged food product or packaged food arrangement thereon or removing/sliding the packaged food product therefrom. When the lid body30is pivoted from the open configuration to the closed configuration, the tilting assembly70returns the lower plate40to its horizontal position.

It is apparent that other embodiments of the tilting assembly70are possible, including those having lifting posts, gears or cams. Referring back toFIGS. 1 to 6, either one or both of the lid body30and the lower plate40is resiliently biased to the open configuration/tilted position by suitable means such as torsion springs39A,46A at the front pivot portion46and the hinge39. The base body20includes a tab stopper28which engages a rear protrusion48of the lower plate40to retain the lower plate40in its horizontal position (and the lid body30in its closed configuration) for a selected cooking period. The tab stopper28can be connected to a cooking timer which releases the lower plate40at the end of the cooking period thus allowing the lower plate40to move to its tilted position. The tab stopper28can be spring loaded, and can comprise a solenoid for releasing the stopper as required.

The upper plate50comprises a heatable lower surface51, and is mounted to the lid body30via a mounting means or mounting mechanism80for movement in a substantially perpendicular (vertical) direction relative to the lower plate40in the closed configuration.

The mounting mechanism80comprises, on each side of the upper plate50, a pair of parallel front and rear arms82and83. The front arms82are pivotably mounted to a front pivot portion54of the upper plate50and to an upper portion37of the side wall32, about halfway between the front wall34and the rear wall33. The rear arms83are pivotably mounted to a rear pivot portion56of the upper plate50and to an upper portion38of the side wall32, adjacent the rear wall33. The arms82and83are parallel to each other and allow the upper plate50to move in a generally vertical direction relative to the lid lower edge36and minimises lateral movement.

The lid body30comprises a retaining assembly90which retains the upper plate50at a predetermined distance from the lower plate40in the final stage of the cooking process according to a preferred embodiment of the present invention.

In the first stage of the cooking process, the lower plate40and the upper plate50are initially adjacent and substantially abutting each other (FIG. 3) with the packaged food product to be cooked being disposed therebetween (first position of the upper plate50). In the second stage, gases and/or steam are produced within the packaged food product which expands the packaging and lifts the upper plate50from the lower plate40(FIG. 4) (second position of the upper plate50). In the third stage, the gases from within the packaged food product are released which allows the upper plate50to move back towards the lower plate [151]40(FIG. 5) (third position of the upper plate50). The retaining assembly90retains a minimum distance between the upper and lower plates50and40during this third stage.

The second position of the upper plate50depends on the expansion of the food product. Depending on the release of the gases from the package, the third position of the upper plate50may be at the minimum distance provided by the retaining assembly90or slightly above this minimum distance.

The retaining assembly90comprises an angle formation member91, an actuation arm92and a retaining arm93. The angle formation member91is mounted to the base body20and extends upwardly from the base upper edge26thereof. The angle formation member91comprises an inclined angle surface.

The actuation arm92and the retaining arm93are both mounted to a pivot block95extending from the lid body30, about respective pivot points96and97. The actuation arm92comprises an angled lower end101and an upper stub102which are disposed on opposite sides of the pivot point96. The retaining arm93comprises an upper portion103and a lower retaining leg104which are disposed on opposite sides of the pivot point97.

The retaining leg104is biased to a position of engagement with the lower surface51or a rear edge52of the upper plate50(FIG. 5), for example by the retaining arm93having torsion springs about the pivot point97as indicated by arrow106. The upper stub102is biased to a position of engagement with the upper portion103(FIG. 6), for example by the actuation arm92having torsion springs about the pivot point96as indicated by arrow107. The torsion force acting on the actuation arm92is greater than the torsion force acting on the retaining arm93.

In the open configuration of the lid body30, the upper stub102engages the upper portion103of the retaining arm93, positioning the retaining leg104to a position of disengagement with the lower surface51or the rear edge52(FIG. 2). This allows the upper plate50to move downwardly past the retaining leg104for the lower surface51to be substantially aligned with the lid lower edge36(first position of the upper plate50).

In the closed configuration of the lid body30, the lower end101engages the angle formation91, moving the upper stub102to a position of disengagement with the upper portion103. This allows the retaining arm93to pivot to bias the retaining leg104toward the upper plate50. Whilst the upper plate50is in its first position, the retaining leg104engages against a rear wall53of the upper plate50. Once the upper plate50is lifted during use toward its second position, the retaining leg104is moved to its engagement position (FIG. 4), at which it can engage the lower surface51or the rear edge52when the upper plate moves to its third position (FIG. 5).

When the food product is cooked, the lid body30is moved to its open configuration at which the lower end101disengages the angle formation91, the upper stub102engages the upper portion103of the retaining arm93, and the retaining leg104is moved to its disengagement position with the lower surface51or the rear edge52(FIG. 6). The actuation arm92thus acts as a release means to allow the upper plate50to move back to its first position.

The first, second and third positions of the upper plate50thus define respective first, second and third relative distances between the lower plate40and the upper plate50.

It is envisaged that in alternative arrangement shown inFIGS. 32-35, one or both of the first heatable plate and the second heatable plate are be biased towards each other by springs85to maintain a consistent (relatively low) force on the packaged food arrangement or package food product as it cooks. It is envisaged that in such an embodiment, the first heatable plate and second heatable plate will be movable relative to each other between an open configuration in which the food product arrangement can be placed between them, and a closed configuration in which they engage opposing sides of the packaged food product (shown inFIG. 29).

When in the closed configuration, the food product200will undergo a cooking process illustrated in order inFIGS. 32-35.

As the packaged food product expands under pressure of the gases within the package food product, the first heatable plate and the second heatable plate will maintain a constant pressure on the package food product, while being moved apart. It is anticipated that the package food product will release the gases within it, for example by rupturing or controlled release of gases through an aperture (not shown) once the food product within is suitably cooked or baked, at which time the first heatable plate and the second heatable plate will move closer to each other again, maintaining the same force (or range of forces) on the packaged food product to ensure the browning or caramelisation of the package food product, without damaging the integrity of the food product structure.

Packaged Food Product

FIGS. 16, 17 and 20show a packaged food arrangement, also referred to as a packaged food product200prior to the cooking process or in the first stage of the cooking process. The packaged food product200comprises an outer packaging portion in the form of an outer package210and a food product220disposed within the package210. The package210is preferably composed of a heat resistant foil, such as a polyethylene terephthalate polyester film, such as that sold under the trade name Mylar by DuPont industries, and allows the food product220to be cooked preferably via heated plate contact with the package210.

The package210generally comprises first and second panels212and214sealed to each other along their peripheral portions216to form a bag defining an internal chamber218therewithin. That the first panel212and second panel214can be heat sealed to each other or be adhered or bonded to each other by a suitable form of food grade approved adhesive, such as a neoprene reacted phenolic adhesive; or a vinyl acetate emulsion adhesive.

The package210can alternatively be formed from a folded elongated material and will thus have one joined edge portion with the other three edge portions216joined to each other to form the package210.

The food product220is disposed within the internal chamber218and can be made from any desired mixture such as a batter based food product for making a cake, a crepe, a pancake or a waffle, or an egg based product for making a quiche, an omelette or cooked egg, or any other similar product as desired. In a preferred embodiment, it is anticipated that the food product220will comprise a baking mix including at least a filler, a binder and a raising agent. The term “raising agent” is defined to include aerators of any form. In a more preferred embodiment, it is anticipated that the food product will be a baking mix including at least a filler, a binder, a sweetener, fat and a raising agent.

Prior to cooking, the packaged food product200is generally flat (FIGS. 17 and 20) and typically stored in a refrigerator or freezer to keep the food product220from spoiling. In the initial stage of the cooking process, the packaged food product200remains in this generally flat configuration with an initial first thickness230and is engaged by the lower and upper plates40and50in the first position of the upper plate50.

In the second stage of the cooking process, the food product220being cooked expands (FIGS. 18 and 21) and produces gases within the internal chamber218, which moves the first panel212away from the second panel214thus expanding the package210. It is anticipated that the gases can be produced from the aerators included in the food product220, or by gasification of liquids such as water (for example as water vapour). The panels212and214remain generally parallel in their expanded configuration. The packaged food product200defines a greater second thickness232and lifts the upper plate50from the lower plate40to its second position.

The packaged food arrangement is preferably adapted for expanding to drive the first panel and the second panel apart from each other under pressure of the gases created during the process of cooking the food product220. It is anticipated that the package210will further be adapted for rupturing at a predetermined pressure and/or volume to release the gas.

In the third stage of the cooking process, the gases within the internal chamber218are released (FIGS. 19 and 22) which allows the upper plate50to move back towards the lower plate40to its third position. The packaged food product200in this stage defines a third thickness234which is between the first and second thicknesses230and232. It is important that when the upper plate moves back towards the lower plate into its third position, the cooked food product is not flattened, and the integrity of the aerated or raised food product is retained.

In this way, correct conditions for the baking of the food product are created within the internal chamber218of the package210(or foil bag), after which time the upper plate50moves back towards the lower plate42ensure a browning or caramelisation effect on both opposed sides of the food product.

However, it is anticipated that the packaged food arrangement need not necessarily be cooked and/or baked by heated plates. In an alternative arrangement, it is envisaged that the outer package can include expansion formations including any one or more selected from concertina formations215(as shown inFIGS. 27 and 28), telescopic formations213(as shown inFIGS. 30-35), and pleat formations217(as shown inFIG. 29) that allow for expansion of the outer package due to the expansion of gases during the cooking and/or baking process. The cooking and/or baking process can be initiated by, for example baking in an oven by conventional convention and radiation from a heat source, irradiating the packaged food arrangement in a microwave oven, steaming, contact with a hot plate, or any other suitable means.

It is anticipated that the packaged food arrangement will preferably be configured in a substantially flat and planar configuration prior to the cooking and/or baking process. In this way, the package food arrangement can be conveniently stored in a freezer or fridge in an efficient manner. It is also anticipated that in a preferred embodiment, the package food arrangement will still be configured as a substantially planar configuration in its cooked state, but thicker.

It is further anticipated that the food product stored within the packaged food arrangement will be freezable.

The inventor has found that the internal chamber218and the gases produced and retained therein during the cooking process provide an optimum environment for the food product220to be cooked and produce a desired cooked product composition and texture.

In some specific food products220, it has been found that minimising the release of the gases from the internal chamber218has been advantageous.

In other specific food products220, it has been found that releasing the gases from the internal chamber218after a predetermined pressure within the internal chamber218is reached has been advantageous. During the cooking process, pressure within the internal chamber218increases as the food product220expands and produces more gases. For some food products220, it has been found that releasing the gases after the pressure within the internal chamber218reaches about 1.5 bar (1.5 atm) is advantageous in producing the desired product texture.

Preferably, the package210includes a releasing arrangement or release means for releasing the gases when this predetermined pressure is reached. The release means can comprise a seal which opens at the predetermined pressure.

In other specific food products220, it has been found that constantly releasing the gases from the internal chamber218at a slow predetermined rate has been advantageous. The release means can comprise at least one aperture of predetermined diameter formed in the package.

The retaining assembly90retains a minimum distance between the upper and lower plates50and40during the third stage of the cooking process which avoids the finished product being squashed down by the weight of the upper plate50.

FIGS. 23 and 24show two alternative packages210band210c, which are both circular disc shaped, with the package210bhaving rounded edges216with a minimal lip and the package210chaving flanged edges216. It is apparent other possible shapes of the packages are possible, including those that form cavities, apertures, textures or shapes to the cooked batter mixture220. The first and/or the second panels212and214can also be resiliently stretchable or expandable to allow for expansion of the package210and also allow textures or embossments to be formed in the cooked product.

FIG. 25shows a first alternative package210bfor a food product. This embodiment comprises first and second spaced panels212and214and a side wall215connecting peripheral portions of the first and second panels212and214to form an internal chamber218therewithin. The at least one side wall215is stretchable or expandable to allow for expansion of the package when the food product therewithin produces gases during the cooking process.

FIG. 26shows a second alternative package210cfor a food product which is similar to the package210b. In this embodiment, the side wall215comprises a concertina structure to allow for expansion of the package.

The first and second spaced panels212and214comprise non-stick, heat resistant, food approved material, which allows the food product to be cooked via heated plate contact with the package.

In one embodiment, the panels212and214are made from baking paper, being silicon coated, non-stick, heat resistant paper. Other suitable food approved material can also be used, such as Teflon® coated material, and others which are heat resistant up to at least 220° C.

In use, the lid body30is initially in the open configuration as shown inFIG. 1and the lower and upper plates40and50are heated. This also corresponds to the open configuration of the lower and upper plates40and50. A packaged food product200is placed onto the top surface42, and can be retained therein by the peripheral border44if it slips. The lid body30is then moved to its closed configuration, at which the lower and upper plates40and50move to their closed configuration and cook the packaged food product200along the three stages described above. Once cooked, the tab stopper28releases the lower plate40which allows the lid body30to move back to its open configuration.

Moving the lid body to its closed configuration can be done manually, at which the lid body30preferably includes a handle, or automatically via motor control. Preferably, the tab stopper is controlled by a cooking timer which automatically releases the lower plate40after the end of the predetermined cooking period. When the lower plate40moves back to its tilted position, the packaged food product200can be slid down the lower plate40to a plate positioned in front of the front wall24. The cooked finished product220is then removed from the package210by peeling the panels212and214from each other. The panels212and214can include peel tabs to assist this action.

Alternatively, the cooked food product220can be retained in its package210which provides hygienic storage for eating of the food product220later. The package210can also be partially opened for use as a container at which a desired sauce can be added to the cooked food product220.

The cooking appliance10is designed for domestic use and is thus sized to sit on top of domestic kitchen bench. The lower and upper plates40and50thus preferably have a maximum length and width of about 20 cm each. The cooking appliance10can have several individual pairs of lower and upper plates40and50laid side by side, with a common lid body30or separate lid bodies30.

Alternatively, the cooking appliance can be sized for small commercial, or large commercial use and can include large size lower and upper plates or a large number of pairs of lower and upper plates.

The preferred embodiment thus provides a packaged food product which is cooked/baked in a package in a cooking appliance which positions the heated plates as required to cook the food product in a manner which provides the desired composition and finish. The package is heat resistant and allows the food product to be cooked via heated plate contact with the package. The appliance and the package can also be used for cooking other products, for example for frying items such as bacon and hamburgers. The present cooking appliance saves time and cooks a product on both sides simultaneously.

In the preferred embodiment, the food product is batter based which bubbles and expands under temperature.

The cooking appliance substantially maintains contact with the packaged food product throughout the three stages of cooking and assists in uniform cooking of the finished product. The retaining assembly90avoids full collapse of the upper plate50to the lower plate40thus maintaining a fluffy texture to the finished product220. The gases produced within the package210assists in cushioning the batter mixture220from the upper plate50, thus allowing the food product220to rise and cook within the internal chamber218with minimal pressure from the upper plate50.

The present preferred embodiment thus allows household users to cook a packaged food product with minimal preparation, mess and cleaning.

FIG. 10shows a cooking appliance10bwhich is a modified embodiment of the cooking appliance10. In this embodiment, the lower plate40pivots about a rear pivot point [196]46and a front end of the lower plate40extends down towards the bottom wall21in the open configuration of the lid body30. The front end of the lower plate40is then raised in the closed configuration of the lid body30. The front wall24in this embodiment may have an opening or a cut-out portion to allow for the food product to slide down from the top surface42.

FIGS. 11 to 15show a third embodiment of a cooking appliance10c. The cooking appliance10cis similar to the cooking appliance10and similar parts are indicated with the similar reference numerals.

In the drawings, several portions of the base body20and the lid body30are omitted for illustration purposes. Only the portions of these parts having the base upper edge26and the lid lower edge36are shown. The lid body30is similarly pivotable relative to the base body20between an open configuration and a closed consideration.

The lower plate40similarly comprises a heatable top surface42. The cooking appliance10calso comprises the tilting assembly70for the lower plate40. The upper plate50also comprises a heatable lower surface51.

In this embodiment, the mounting mechanism80for the upper plate50comprises spaced posts82amounted to the lid body30and extending generally perpendicularly to the lid lower edge36. The upper plate50comprises ring formations59respectively engaging and movable along the posts82ato allow the upper plate50to move in a generally perpendicular (vertical) direction relative to the lid lower edge36in the closed configuration and minimises lateral movement.

The lid body30can also comprise a retaining assembly90which will retain the upper plate50at a predetermined distance from the lower plate40in the final stage of the cooking process, which can be of different configuration to the retaining assembly90above.

The first and second plates40and50in the above embodiments comprise flat heatable surfaces in the form of top surface42and lower surface51.

Alternatively, at least one of the top surface42and lower surface51can be textured as desired, for example for cooking waffle products or producing embossments in the cooked product.

Whilst preferred embodiments of the present invention have been described, it will be apparent to skilled persons that other modifications can be made to the embodiments described.

For example, depending on the food product, the third stage of the cooking process may not be required and can be omitted. This can be used for example for cooking any unpackaged food product. Also, the retaining assembly can be disengaged if a flat finish to the food product is desired. The retaining assembly can also be modified such that the first, second and/or third relative distances between the plates are adjustable, and that the second relative distance can be up to a maximum selected distance.

The cooking appliance can also be modified to have both the upper and lower plates movable relative to each other. Also, the plates can be oriented to be substantially vertical instead of horizontal. The plates can alternatively be oriented at an inclined angle in the closed configuration.

The first and second plates are also substantially parallel to each other in the closed configuration. In another embodiment, the first and second plates can be at an acute angle to each other in the closed configuration, for producing wedge shaped cooked products.

Interpretation

Embodiments

Different Instances of Objects

Specific Details

Terminology

In describing the preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “forward”, “rearward”, “radially”, “peripherally”, “upwardly”, “downwardly”, and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

Comprising and Including

Any one of the terms: including or which includes or that includes as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, including is synonymous with and means comprising.

Scope of Invention

INDUSTRIAL APPLICABILITY

It is apparent from the above, that the arrangements described are applicable to the food and kitchen appliance industries.