Patent Abstract:
The present disclosure describes a pan formed from a base plate, a housing, a divider and an ejection plate. Together, the pan is shaped to form a pocket bun. The constituent parts of the pan nest together when baking, and disassemble when removing the bun from the pan. The pocket bun has an open-mouth design to allow ingredients to be retained in the bun while the sandwich is being consumed. The open-mouth design is formed having either a single cavity or a plurality of cavities, with each cavity adapted for carrying a filling. The pan is designed having one or more chambers, with each chamber adapted for baking a bun. Adjacent chambers optionally include openings therebetween such that adjacent buns will have a baked connection therebetween.

Full Description:
BACKGROUND OF THE INVENTION 
     A typical sandwich is formed having a filling disposed between two pieces of bread. A hamburger is one common sandwich, with a ground beef patty, vegetables and condiments disposed between an upper and lower bun. Sometimes the bread is hinged, such as is used with a hotdog or sausage. The common failing of these types of sandwiches is that they can be difficult to eat tidely when on the go—the sandwich filling can leak out of the bread while being eaten. As such an improved bun is needed for containing sandwich filling. The disclosure provided herein describes an improved pan for baking a bun suitable for use in making a variety of sandwiches (including, but not limited to, hotdogs, sausages, hamburgers, sub sandwiches, loose meat sandwiches, among many others). 
     SUMMARY OF THE INVENTION 
     The present disclosure describes a pan for preparing an improved bun suitable for making various types of sandwiches. The pan described herein is composed of a base plate, a housing, an ejector plate and a divider. The pan, when assembled, is shaped to form a pocket bun therein. The pan is designed to be disassembled in a way to allow ready ejection of the pocket bun from the pan. 
     The pan may include a single chamber for producing a single bun, or multiple chambers for producing multiple buns from a single pan. One chamber may include a single male mold for producing a bun having a single cavity, or multiple male molds for producing a bun having multiple cavities. The divider separates the chambers and may include openings to allow buns in adjacent chambers to form a baked connector therebetween for holding the buns together during packaging. 
     The pan of the present disclosure includes further improvements over previous pans, including providing a pan with means for ejecting deep-draw goods from the pan such as through a pneumatic system or use of ejection pins. In one configuration, the pan of the present disclosure produces a bun having a plurality of cavities, such that food stuffs are independently insertable into each cavity. In an additional configuration, the shape of either the exterior of the bun or the cavity of the bun is formed with a distinctive shape so as to provide unique brand-identifying capabilities. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A preferred embodiment of this invention has been chosen wherein: 
         FIG. 1  is a perspective view of a pan suitable for forming one or more hamburger-accommodating pocket buns; 
         FIG. 2  is an exploded view of the pan of  FIG. 1 ; 
         FIG. 3  is a top view of the pan of  FIG. 1 ; 
         FIG. 4  is a sectional side view of the pan of  FIG. 3  as taken along line  4 - 4  and shown housing two buns; 
         FIG. 5  is a perspective view of a pan suitable for forming one or more hotdog-accommodating pocket buns; 
         FIG. 6  is a sectional side view of the pan of  FIG. 7  as taken along line  6 - 6  shown housing two buns; 
         FIG. 7  is a top view of the pan of  FIG. 5 ; 
         FIG. 8  is an exploded view of the pan of  FIG. 5 ; 
         FIG. 9  is a perspective view of a pan showing the male mold having an octagon-shaped cross-section; 
         FIG. 10  is a perspective view of a pan showing the male mold having an oval-shaped cross-section; 
         FIG. 11  is a sectional side view of the pan of  FIG. 1  and showing the ejector pins; 
         FIG. 12  is a sectional side view of the pan of  FIG. 10 , and showing an alternative ejector system; 
         FIG. 13  is a top view of a pan showing a divider providing an octagon-shaped outer cross-section to the buns; 
         FIG. 14  is a top view of a pan showing a divider providing an oval-shaped outer cross-section to the buns; 
         FIG. 15  is a sectional side view of a pan for forming a single bun having two cavities; and 
         FIG. 16  is a perspective view of a bun formed from the pan of  FIG. 15 . 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present disclosure describes a pan  10  suitable for preparing a pocket bun  12 . Pocket bun  12  is a molded object one embodiment of which is shown in  FIG. 16 , such as a food product or bun, formed having a wall  14  which defines a cavity  16  (other embodiments of bun  12  are shown in side-view in  FIGS. 4 ,  6 ,  11 ,  12 , and  15 , where  FIG. 16  shows a two-cavity bun, and the remaining figures show single-cavity buns). An opening  18  is formed through wall  14  and allows access to cavity  16 . Cavity  16  and opening  18  together form an open mouth in pocket bun  12 , with cavity  16  suitable for carrying food products, such as a hamburger, a hotdog, cold cuts, or any other food products and related condiments and dressings. The present disclosure is directed to pan  10 , any references to pocket bun  12  should not be seen as limiting the uses of pan  10 . It is understood that bun  12  formed in pan  10  is suitable for carrying a variety of sandwich fillings, and any reference to a specific type of filling is merely illustrative and does not limit the use of the bun. For example, any reference to hotdogs is only to illustrate the general shape of the bun, not to limit the bun from being used with other types of fillings. 
     As described herein, pan  10 , and associated parts described in detail below, are referred to as having upper and lower ends. These designations are for ease of reference herein, with the upper end referring generally to the open top of pan  10 , and the lower end referring generally to the base of pan  10  opposite the open top. It is understood that as used, pan  10  is positionable in any number of orientations, and as such any reference to upper and lower is not seen as limiting. 
     Pan  10  is formed from a group of nestable parts: a base plate  20 , a housing  22 , an ejection plate  24  and a divider  26 , as shown assembled in  FIG. 1  and in exploded view in  FIG. 2 . Base plate  20  is a generally flat plate having an aperture  28  passing therethrough and spaced inwardly from an outer edge  36 . A male mold  30  extends from a top side  32  of base plate  20 . Male mold  30  circumscribes aperture  28 , such that male mold  30  defines a cavity  34  having an opening defined by aperture  28  (cavity  34  shown in  FIG. 4 ). Male mold  30  is preferably tapered such that a cross-section of male mold  30  taken parallel to and proximate base plate  20  is larger than a cross-section of male mold  30  taken near the upper end. Male mold  30  is tapered to aid in ejecting bun  12  from pan  10 . As shown in  FIGS. 1-3 , male mold  30  has a generally rectangular cross-section, though other cross-sections are suitable, see, for example,  FIGS. 5-8  (round cross-section),  FIG. 9  (octagon cross-section), and  FIG. 10  (oval cross-section). Base plate  20  may include a single aperture  28 /mold  30  combination, such as for preparing a single pocket bun  12 , or alternatively may include an array of aperture  28 /mold  30  combinations (as shown in  FIG. 2 ), such as for preparing multiple pocket buns  12  using a single pan  10 , or for preparing a single bun  12  having multiple cavities  16  (as shown in  FIG. 15 ). 
     Housing  22 , as shown in  FIG. 2 , is formed having an upright wall  38  defining an interior space, with a lip  40  extending inwardly from and inscribing the lower end of upright wall  38 . When pan  10  is assembled, lip  40  overlies base plate  20 . As shown in  FIGS. 3 and 4 , upright wall  38  is tapered such that the upper end is wider than the lower end, to ease removal of pocket bun  12  from pan  10 . A guide  42  is positioned on the interior face of upright wall  38 , with the guide formed from a first rail  44  and a second rail  46 . First rail  44  is positioned generally vertically, and second rail  46  is offset from, and generally parallel to first rail  44 . Rails  44 ,  46  are offset from one another such that a gap  48  is formed therebetween. The embodiment of housing  22  shown in  FIG. 2  includes a pair of guides  42  positioned on facing surfaces of upright wall  38 . In other embodiments, the number and positioning of guides  42  is variable depending on the number and positions of the aperture  28 /mold  30  pairs of base  20 . In additional embodiments, guides  42  are omitted from housing  22 . It is contemplated that base  20  includes notches  37 , such that base  20  is alternatively positionable sandwiched between housing  22  and ejector plate  24  with notches  37  locating base  20  relative housing  22 . 
     Ejection plate  24  is defined as a generally flat plate having an outer edge  50 . With pan  10  assembled, ejection plate  24  overlies lip  40  of housing  22 . A notch  52  forms an indentation in edge  50 , with notch  52  sized to straddle guide  42  when pan  10  is assembled, thereby notch  52  locates ejection plate  24  relative housing  22 , as shown in  FIG. 3 . Ejection plate  24  includes an aperture  54  formed therethrough, aperture  54  is sized at least as large as the largest cross-section of mold  30 , such that aperture  54  encircles mold  30  when pan  10  is assembled. 
     Divider  26  is defined as an upright plate overlying ejection plate  24  and subdividing the interior of housing  22  into multiple chambers. In the embodiments shown in  FIGS. 2 and 8  divider  26  is X-shaped, with four plates joined together at the intersection formed therebetween. With pan  10  assembled, an outer edge  56  of divider  26  is located at gap  48  between first rail  44  and second rail  46  of guide  42 , such that guide  42  retains divider  26  at a specified position within housing  26 . Divider  26  includes a gap  58  formed at the bottom edge of divider  26 .  FIGS. 3 and 7  show a top view of pan  10  as assembled, where divider  26  is used to subdivide the pan into four quadrants, with each quadrant forming a chamber suitable for baking a pocket bun  12 . Gap  58  provides an opening between adjacent chambers to allow adjacent pocket buns  12  to be joined together, such as to aid in keeping groups of pocket buns  12  together during processing or shipping. Gap  58  may be positioned at any of many suitable positions on divider  26 , such as at the outer corners of divider  26  or at the intersection between the plates, or spaced between the corners and intersection as is shown in  FIG. 2 . It is contemplated that gap  58  may be omitted, thereby providing a pan  10  which completely segregates buns  12   
     It is contemplated, such as is shown in  FIGS. 13 and 14 , that divider  26  is shaped other than as an X to form buns of different shapes. It is also contemplated that divider  26  may be omitted and the resulting buns may be sliced into individual buns in a separate step. It is contemplated that gap  58  is omitted such that divider  26  forms a complete partition between adjoining chambers. 
       FIG. 3  is a top view of pan  10  showing ejection plate  24  overlying lip  40  of housing  22  (lip  40  shown in dotted line). Notch  52  of ejection plate  24  locating ejection plate  24  in house  22  relative guide rails  44 ,  46 . Male molds  30  are shown extending up through ejection plate  24 . It is contemplated that ejection plate  24  may be omitted. 
       FIG. 4  shows a side view of pan  10 . Pocket bun  12  is shown in pan  10 .  FIG. 4  shows how the constituent parts of pan  10  stack together, with divider  26  overlying ejection plate  24 , ejection plate  24  overlying lip  40  of housing  22 , and lip  40  overlying base  20 . Male mold  30  extends upwardly through ejection plate  24  into housing  22 . 
     Referring now to  FIGS. 5-8 , in one embodiment pan  10  is shaped to form a bun  12  suitable for carrying a hotdog and associated condiments. As will be appreciated by comparing  FIG. 1  and  FIG. 5 , each embodiment includes the same constituent parts: base  20 , housing  22 , ejection plate  24  and divider  26 , the main difference being the relative dimensions and shape of the parts. For example, housing  22  of  FIG. 5  is generally taller than that of  FIG. 1  to allow for the forming of a long bun shaped to carry a hotdog. Similarly, male mold  30  of  FIG. 5  has a circular cross-section to accommodate a hotdog. 
       FIG. 8  shows an exploded view of the constituent parts of the pan  10  of  FIG. 5 .  FIG. 8  shows housing  22  and lip  40 , with lip  40  contoured to match the shape of male molds  30 . Base  20  includes spacers  60  which serve to locate housing  22  on base  20 . Spacers  60  are raised bosses or strips extending from the surface of base  20  which contact the outer wall of housing  22  when pan  10  is assembled.  FIG. 1  shows an embodiment of pan  10  which omits spacers  60 . It is envisioned that pan  10  of  FIG. 1  could be modified to include a spacer  60  by enlarging the dimensions of base  20 . Likewise, it is envisioned that pan  10  of  FIG. 8  could be modified to omit spacer  60 . 
       FIG. 6  shows a cross-sectional side view of the embodiment of pan  10  showing how the constituent parts overly one another in assembled form.  FIG. 6  is comparable to  FIG. 4 . Similarly,  FIG. 7  is comparable to  FIG. 3  in showing a top view of the respective embodiments of pan  10 . 
       FIGS. 9 and 10  show alternative shapes of male mold  30 .  FIG. 9  shows male mold  30  having an octagon-shaped cross-section.  FIG. 10  shows male mold  30  having an oval-shaped cross-section. As is clear from  FIGS. 9 and 10 , male mold  30  is formable in any one of many possible cross-sectional shapes, which in turn forms the internal cavity of pocket bun  12  in the corresponding shape. As such, the shape of male mold  30  can be customized to allow for a specific type of food, or to allow for distinctive marketing or branding. The shape of male mold  30  may be customized on either the hamburger or hotdog accommodating bun pans. The cross-sections shown herein are merely illustrative, and should not be viewed as limiting. Such cross-sections are preferably polygon shaped. Such cross-sections are more preferably equi-angular polygons such as: triangle, square, pentagon, hexagon, heptagon, or octagon. Other shapes which provide brand-identification are suitable. 
       FIG. 11  shows a sectional side view of pan  10 , showing an auto-ejection system having ejection pins  62 . Ejection pins  62  pass through apertures in base  20  such that when actuated, ejection pins  62  apply a force to ejection plate  24 , to force bun  12  away from pan  10 . Ejection pins  62  may be mechanically, pneumatically, electrically, manually, or otherwise actuated. Alternatively, ejection plate  24  is omitted and ejection pins  62  force housing  22  away from base  20 , and housing  22  urges bun  12  out of pan  10 . It is contemplated that base plate  20  is carried above lip  40  of housing  22 , such that pin  62 , when actuated, forced base  20  up and away from housing  22 . Additionally, it is contemplated that pin  62 , when actuated, contacts bun  12  directly, causing bun  12  to come free from pan  10 . 
       FIG. 12  shows a sectional side view of pan  10  having an air manifold  64  for providing a pneumatic release system to pan  10 , whereby air is used to force bun  12  free from pan  10 . Manifold  64  is in fluid communication with apertures in male mold  30 , such that when activated, air forces bun  12  away from pan  10 . It is contemplated that ejector plate  24  may be omitted where manifold  64  is used to eject bun  12  from pan  10 . 
       FIGS. 13 and 14  show alternative shapes of divider  26 , such as to form a pocket bun  12  having an octagon-shaped outer cross-section (as in  FIG. 13 ), or a pocket bun  12  having an oval-shaped outer cross-section (as in  FIG. 14 ). The shape of divider  26  may be selected to yield the outer cross-section desired for a given pocket bun  12 . The outer cross-section and cavity cross-section of pocket bun  12  may each be independently selected to yield a pocket bun  12  having desired characteristics, such as for brand identification or similar distinctive aesthetic enhancement of bun  12 . The cross-sections shown herein are merely illustrative, and should not be viewed as limiting. Such cross-sections are preferably polygon shaped. Such cross-sections are more preferably equi-angular polygons such as: triangle, square, pentagon, hexagon, heptagon, or octagon. Other shapes which provide brand-identification are suitable. 
     In one embodiment, a bun is formed having a pair of inner chambers. This embodiment is useful for building a three-layer sandwich, such as bun-filling-bun-filling-bun, as is common at some fast food restaurants. An example of this embodiment is shown in  FIGS. 15 and 16 . Here, pan  10  includes a pair of male molds  30  without a divider between them such that a bun  12  is formed having a pair of cavities. The dimensions shown in  FIG. 16  are merely illustrative, the dimensions of bun  12  (such as the thickness of wall  14  or the relative size of cavity  16 ) may be varied according to the type of bun which is desired. The same can be said for a bun formed having a single cavity. 
     One advantage of bun  12  formed by pan  10  over prior art breads is that pan  10  forms a bun where both the outer surface and the cavity surface of bun  12  has a browned surface. Most buns, for example a common hamburger bun, have a browned outer surface, but the inner surface is not browned, but is formed by splitting the bread open. The present bun  12  includes an inner cavity having a browned surface such that when a filling is placed in the bun the filling contacts a browned surface and the browned surface serves to minimize the bread becoming soggy by resisting absorption of moisture from the filling. In this way, pan  10  bakes a bun  12  which resists becoming soggy. 
     The outer surface of bun  12  is browned either by direct contact from heated air when baking (such as is the case at the open top of pan  10 ), or by conductive heat transferred from pan  10  to the bun. Base plate  20  includes apertures  28  through which heated air enters the internal cavity of male mold  30 , such that male mold  30  is heated during baking so as to brown the inner cavity  16  of bun  12 . Browning the inner cavity  16  of bun  12  provides the beneficial effect of forming a filling-accepting portion of bun  12  which is resistant to becoming soggy. 
     Pan  10  is formed from a material sufficient at least to withstand the heat of baking, to retain shape when baking, and to transfer heat to brown bun  12  when baking. Such materials include, but are not limited to, aluminum, steel and other metals, silicone, tempered glass, ceramic, or composite. Any of such materials may include a non-stick coating. 
     Pan  10  is formed having an open top wherein the open top allow gases to escape from the pan when bun is being baked. 
     It is understood that while certain aspects of the disclosed subject matter have been shown and described, the disclosed subject matter is not limited thereto and encompasses various other embodiments and aspects. No specific limitation with respect to the specific embodiments disclosed herein is intended or should be inferred. Modifications may be made to the disclosed subject matter as set forth in the following claims.

Technology Classification (CPC): 0