Patent Publication Number: US-2003221535-A1

Title: Structure and method for cutting slabs of natural cheeses into shape (s) via cutting blades of a pattern such that the shape (s) are tessellated or nested

Description:
RELATED APPLICATION  
     [0001] This patent application claims the benefit of U.S. Provisional Application No. 60/369,139, filed on Apr. 1, 2002. 
    
    
     
       BACKGROUND OF THE INVENTION  
       [0002] This invention relates generally to the field of cutting patterns out of materials, and specifically to the cutting of nested, mosaic, or tessellated patterns from a slab or block of food product, e.g., cheese.  
       [0003] It is commercially desirable to provide food products in a variety of shapes that are appealing to consumers, e.g., cubes, stars, hearts, moons, various animals, various plants, various representations of real people or fictional characters, various shapes, various figures, etc. Typically, the production of such shapes and designs produces a commercially undesirable level of waste product, sometimes referred to as trim or “fines.” It is the object of the present invention to provide for the production of such shapes through the use of specially designed tooling to provide a system, by which such food products of various shapes may be produced with little or no waste product, i.e., fines.  
       SUMMARY OF THE INVENTION  
       [0004] The process and system of the present invention may include pre-cutting a target food product into slabs. The slabs produced by this initial cutting step are within a predetermined size range, i.e., predetermined range as to height, length, and width. After a slab of target food product is cut so that it is of a size that is within the predetermined boundary of the predetermined size range it is introduced to a cutting tool at a predetermined time and at a predetermined speed.  
       [0005] A cutting tool according to the present invention is of a predetermined size and includes at least one cutting blade. The cutting blade preferably includes a cutting edge having a contour defining a shape that is at least sufficient to cut a predetermined pattern of tessellated or nested figures out of the slab of food product.  
       [0006] A preferred cutting tool may be in the form of a flat die having a laterally extending lattice cutting blade capable of cutting a predetermined pattern, and may include a knockout block for removing the cut pieces from the die. Alternatively, the cutting tool may be in the form of a rotary cutting tool having a radially extending lattice cutting blade capable of cutting a predetermined cutting pattern. 
     
    
    
     DESCRIPTION OF THE DRAWINGS  
     [0007]FIG. 1 is a perspective view of the apparatus according to the present invention.  
     [0008]FIG. 2 is an exploded view of the apparatus shown in FIG. 1.  
     [0009]FIG. 2A is an enlarged, exploded view similar to that of FIG. 2, but particularly showing the die plate and knockout block.  
     [0010]FIG. 2B is an enlarged, fragmentary, exploded view with partial cross section of the portion of the die plate and knockout block shown generally in FIGS. 2A as  2 B.  
     [0011]FIG. 3 is a fragmentary section view of the apparatus seen in FIGS.  1 - 2 B, taken along line  3 - 3  of FIG. 1 and showing the die plate in the retracted position.  
     [0012]FIG. 3A is a fragmentary section view similar to that of FIG. 3, but showing the die plate in cutting position.  
     [0013]FIG. 4 is a side plan view of the apparatus shown in FIGS.  1 - 3 , but showing the apparatus in conjunction with an optional cheese block cutting assembly.  
     [0014]FIG. 5 is a side plan view of the apparatus shown in FIGS.  1 - 4 , and further showing a pre-sliced slab of food product in ready position relative the cutting area of the apparatus and prior to being cut into desired shapes.  
     [0015]FIG. 6 is a side plan view similar to FIG. 5, but showing the die plate lowered into cutting position relative to a slabbed food product.  
     [0016]FIG. 6A is an enlarged fragmentary perspective view of area  6 A of FIG. 6.  
     [0017]FIG. 7 is a side plan view similar to those of FIGS. 5 and 6, but showing the die plate lifting from the cut food product and retracting into the knockout block, thereby forcing the cut food product from the die plate.  
     [0018]FIG. 8 is a side plan view similar to those of FIGS.  5 - 7 , but showing the die plate in an optional, secondary, partially extended position.  
     [0019]FIG. 9 is a side plan view similar to those of FIGS.  5 - 8 , but showing the die plate in a resting position and retracted into the knockout block.  
     [0020]FIG. 10 is a side plan view of an alternative method and structure of the present invention including discharge of the cut pieces of food product into the interior of a rotary cutting wheel and the use of pressurized air to remove the cut pieces of food product.  
     [0021]FIG. 11 is a perspective view of another alternative cutting tool design having removable or demountable cutting dies as well as open or non-cutting areas.  
     [0022]FIG. 12 is a side view of an alternative procedure and structure of the present invention.  
     [0023]FIG. 13 is a side plan view of another alternative structure and method of the present invention.  
     [0024]FIG. 14 is a perspective view of yet another alternative cutting tool arrangement including a tumbler and a feeder tube through which a predetermined material, such as a coating material, may be added to the cut pieces of food product.  
     [0025]FIGS. 15 through 25 disclose a variety of alternative cutting patterns into which a cutting edge may be formed and that may be employed to cut a food product with minimal or zero waste, with FIGS.  15 A- 15 E illustrating views of a food product cut according to the cutting pattern of FIG. 15, by way of example. 
    
    
     DETAILED DESCRIPTION  
     [0026] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention, which may be embodied in other specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.  
     [0027] The invention may be practiced as illustrated in the Figures. With particular reference to FIGS.  1 - 9  the structure and method of a preferred embodiment of the present invention may be seen. As seen particularly in FIGS.  4 - 9 , slabs  10  of a food product  12 , such as cheese, are pre-positioned and ready for introduction to a cutting die  20 , having a predetermined cutting pattern. The predetermined pattern configured of the die  20  is capable of cutting or stamping an introduced slab  10  of predetermined thickness into tessellated or nested figures of food product. See, e.g., FIGS.  15 - 26 , which show some suggested types of cutting patterns that could, without limitation, be used.  
     [0028] As shown in FIGS.  1 - 2 B, inclusive, an apparatus  14  according to the present invention may be seen. The apparatus  14  as shown is a press type cutter and preferably utilizes a vertical motion to cut slabs  10  of food product  12  (see FIG. 4). The apparatus  14  preferably includes a support workstation  16  for supporting feeder means, seen herein as a belt-type conveyer  18  and other apparatus components as will hereinafter be described. The apparatus  14  further preferably includes a planar cutting die  20  having a plurality of laterally extending cutting knives  22  (see FIGS. 2A and 2B). The cutting knives  22  are preferably arranged in a predetermined latticed cutting pattern  24  corresponding to the shape of food desired. Since a desired goal of the present invention is to minimize waste, such as trim or “fines” during a cutting procedure, a latticed cutting pattern  24  according to the present invention preferably includes a nested or tessellated configuration.  
     [0029] Seen particularly in FIGS. 2 through 2B, the apparatus  14  may further include a knockout block  26 . The knockout block  26  is arranged to knock out the individual cut food products  17  (depicted in FIG. 7) from the cutting die  20  after the slab  10  of food product  12  has been cut. To accomplish this task, and as seen particularly in FIG. 2B, the knockout block  26  preferably includes a plurality of downwardly protruding knockout shapes  27  each having a knockout surface  28 . The knockout surfaces  28  each define a predetermined perimeter  29 . The perimeter  29  of each knockout surface  28  preferably adjoins and defines a re-entrant channel  30 . The channels  30  form an interlocking pattern, which preferably corresponds to the predetermined cutting pattern  24  of the cutting knives  22 . As seen particularly in FIG. 3, this arrangement allows the cutting knives  22  to retract into the respective channels  30  of the stationary knockout block  26  when withdrawn between cutting actions. Further, and as seen in FIG. 7, the knockout surfaces  28  are adapted to urge the cut food product from the cutting die  20  after cutting. It is to be understood that while the various Figures depict knockout surfaces  28  that correspond to the shape of the desired, finished food shape, other knockout surface configurations may be envisioned. Minimally, the knockout surfaces  28  are of at least a shape and size able to fit inside a respective knife shape profile, thereby knocking out the cut food  17  from within the knife perimeter, which perimeter will hereinafter be described and discussed. Further, the knockout surfaces  28  may be optionally provided with a raised or countersunk surface (not shown), to thereby allow for embossing, stamping, or imprinting the cut food  17 . An example of a cut food  17  having an embossed portion  120  may be seen in FIGS.  15 - 15 E, by way of example.  
     [0030] As may be seen particularly in FIGS. 2A and 2B, the individual knockout shapes  29  are preferably of a predetermined height H. The predetermined height H may be of any acceptable height, but is preferably of a height at least corresponding to the height H of the cutting knives  22 . In particular, as seen in FIG. 3, the individual heights H of each knockout shape  27  may vary in the staggered pattern shown. A staggered height pattern provides a more even force distribution across the cutting die  20  when the cut food product  17  is forced from the cutting die  20  after cutting (see FIG. 7), and thereby having a greater efficiency of design.  
     [0031] Referring now to FIGS.  1 - 3 , the various components of a preferred apparatus  14  according to the present invention may be seen. As mentioned earlier, the apparatus  14  preferably includes a support workstation  16 . A prime mover, seen as an air operated cylinder and piston  32  is supported by the workstation  16 . While the various Figures depict an air operated cylinder and piston  32  as the prime mover, it is within the province if the present invention to use other prime movers, such as solenoids, linear servos, cams or other known means. A reciprocating, movable operating cross bar  34  is threadingly connected with an operating rod  36  extending from the prime mover (as detailed in FIG. 3A). The reciprocating, movable operating cross bar  34  is attached to at least one vertically operating traveling member  38 , with two, oppositely disposed traveling members  38  being shown in the Figures. The vertically operating traveling member  38  further includes a secondary cross bar  40  having upwardly extending threaded studs  42 . The threaded studs  42  are adapted to be received by through bores  41  located in the cutting die  20 . The threaded studs  42  are further adapted to be received and threadingly seated in threaded apertures  44  formed in the lower ends  46  of a respective extension  48 . The extensions  48  each include an upper end  50  having a threaded portion  52  to be threadingly received by manually operable wing nuts  54 . Although other fastening means may be envisioned, wing nuts  54 , as shown, are preferred for ease of breakdown and setup of new die and knockout combinations. The upper end  50  is further adapted to be received by a corresponding through bore  56  in an upper cross bar  58  and sufficiently extending to be threadingly received by manually operable wing nuts  54 . While the Figures illustrate a pair of generally parallel cross bars  58  the invention may be practiced with other numbers of cross bars  58 .  
     [0032] The workstation  16  further includes upright support posts  60 . The support posts preferably each include an upper end portion  62  adapted to be slidingly received by through bore  64  of cutting die  20 , a first upper portion  66  adapted to be received by through bore  68  in knockout block  26 , and a second, threaded upper portion  67  to be threadingly received by wing nuts  54 . This arrangement effectively secures the stationary knockout block  26  to the workstation, while allowing for vertical movement of the cutting die  20 .  
     [0033] As may be seen in the Figures, the upper pair of parallel cross bars  58  further preferably includes transversely disposed supports  70 , each of which include a plurality of downwardly extending rod members  72 . The rod members  72  are slidably engaged by corresponding cooperating apertures  74  (seen particularly in FIG. 2B) in the stationary knockout block  26  and extend downwardly to rest upon the upper surface  76  of the cutting die  20 . As may be seen particularly in FIG. 6A, the rod members  72  preferably rest upon the upper surface  76  at pre-selected intersections  78  of the lattice cutting pattern  24 . The rod members  72  provide equal distribution of force throughout the top surface  76  of the cutting die  20  during the cutting process.  
     [0034] Referring now to FIGS.  4 - 9  the process and method of the present invention may be seen. As may be seen particularly in FIG. 4, slabs  10  of a food product  12 , such as cheese, are introduced to a cutting die  20  having a predetermined cutting pattern  24  as discussed previously. The predetermined pattern  24  is capable of cutting an introduced slab  10  into tessellated or nested figures of food product. See, e.g., FIGS.  14 - 26 , which show some suggested types of cutting patterns that could, without limitation, be used. As seen in FIG. 4, slab  10  may be sliced from a block  12  of cheese, or other acceptable food product, to a predetermined thickness by a slicing tool  80 , as shown as part of the method, or may be precut prior to being introduced to the apparatus  14 . The slab of food product  10  is moved by conveyor  18 , as shown in the Figures, or by other means, to a position directly below a cutting die  20  (shown in FIG. 5). The piston of the prime mover  32  (not seen in this view) moves the operating cross bar  34  and vertical traveling member  38  and, as seen by the arrows in FIG. 6, thereby lowers the cutting die  20  toward the slab  10 . The knives  22  of the cutting die  20  are thereby pressed into the slab  10 . As seen in FIG. 7, as the cutting die  20  is retracted into the countersunk channel  30  of knockout block  26 , the now cut food product  17  is urged from the cutting die  20  by the knockout surfaces  28  (described earlier with reference to FIG. 3).  
     [0035] As may be seen in FIGS. 8 and 9, the method of the present invention may preferably further include the optional step of partially lowering the cutting die  20  after a first cut has been made, and retracting the cutting die  20  for a second time into the countersunk channel  30  of the knockout block  26 . This optional step ensures removal of all cut food  17  from the cutting die  20  and knockout block  26  prior to cutting the next incoming slab  10 .  
     [0036] With attention to FIG. 10, an alternative embodiment cutting apparatus  90  may be seen. As shown, slabs  10  of a food product  12 , such as cheese, are introduced to a rotary cutting die  90 , having a predetermined cutting pattern  24  (See FIGS.  15 - 25 , which show some suggested, non-inclusive types of cutting patterns that could be used), and a compression wheel  92 . As is further seen, the slab  10  is fed into a pinch point  94 . The compression wheel  92  forces the slab  10  into the cutting pattern  24  of the cutting wheel  90 . Substantially, the entire slab  10  is cut into individual pieces  17  as determined by the cutting pattern  24  that is used; very little or no waste material, i.e., material that cannot now be packaged, is produced. The resulting cut pieces  17  may then either be allowed to fall into the interior  95  of the cutting wheel  90  and tumble out an end  96  or, alternatively, may be carried between the cutting blades  97  of the cutting pattern  24  and discharged tangentially at a later point in the rotation via any number of means such as gravity, centrifugal force, an automated plunger, application of compressed air, etc.  
     [0037] Similarly to the previously described embodiment, and to ensure that the cutting pattern  24  is in appropriate position, the cheese slabs  10  are advanced via a conveyor belt  18  that operates at a predetermined speed. As noted previously the cheese slabs  10  all fall within a predetermined size range. A sensor  98  may be used to ascertain the position of the cheese slab  10 . An encoder  99  is preferably communicatively coupled to servomotors  100  that are operatively coupled to both the cutting wheel  90  and the compression wheel  92 . The encoder  99  tells the servomotors  100  the speed of the belt  18  and thus the speed of the slab  10 . The servomotors  100  then match the speed of the belt  18 . The servomotors  100  are capable of adjusting the speed of the cutting wheel  90  and the compression wheel  92  to match the speed of the cheese slab  10 . The cutting pattern  24  of the cutting wheel  90  is at a known starting position. The servomotors  100  preferably cause both the cutting wheel  90  and the compression wheel  92  to rotate at a speed that matches the speed of the slab  10  and at a time that cutting pattern  24  is in position to cut the slab  10 . Alignment with both the compression wheel  92  and the cutting wheel  90  is preferably maintained by use of side belts (not shown). In this manner slab  10  after slab  10  may be cut and the resulting pieces  17  packaged.  
     [0038] A specific example of an alternative embodiment of the present invention may be seen in FIG. 11. The alternative embodiment shown may include a cutting wheel  90  comprised of first and second cutting sections  102  and first and second non-cutting sections  104 . The first cutting section  102  will cut a particular pattern out of a first slab  10  of predetermined food product, such as cheese. The first non-cutting section  104  will sequentially follow the first cutting section  102  to allow for discharge of the now cut pieces  17  of the first slab  10  of cheese as well as separation from the subsequent type of cheese slab  10  entering the second cutting section  102 . The non-cutting sections  104  allow the cut pieces  17  to fall through for packaging.  
     [0039] Another alternative embodiment may employ the use of a cutting wheel  90  having first and second cutting sections  102  in conjunction with a compression belt (not shown) instead of a compression wheel  92  as illustrated.  
     [0040] Alternatively, and as seen in FIG. 12, the cutting wheel  90  may be replaced by a reciprocating cutting plate  106  having a cutting pattern  24  (not shown). The cutting plate  106  preferably matches the, speed of the slab  10  advanced from belt  18  and slides the slab  10  under a compression wheel  92  whereby slab  10  would be forced onto and through cutting pattern  24  producing cut pieces  17  with minimal or no waste.  
     [0041] As seen in FIG. 13, a vented belt  110  may be substituted for belt  18  and a vacuum chamber  112  used to apply a negative pressure to hold the slab  10  down and against belt  110  during and after the application of a reciprocating cutting head  90   a.  Thereby holding the cut pieces  17  in place on the belt  110  until after they have been advanced past the reciprocating cutting head  90   a.    
     [0042] Another arrangement may be seen in FIG. 14. Here, a rotary cutting tool  90  may include a cutting pattern portion  24  and a tumbler  114 . The cut pieces (not shown in this view) are allowed to fall into the interior  95  of the tool  90  wherein a feeder  116  may introduce a coating such as an anti-caking agent, for example (not shown) to the cut pieces  17 .  
     [0043] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.