Abstract:
A modular processing device and method of using the modular processing device are disclosed. The modular processing device has a plurality of processing modules removably mounted therein. The processing modules are operable alone or as a group to process an item that is placed in the modular processing device.

Description:
RELATED APPLICATION 
     The present application claims the benefit of U.S. Provisional Application No. 60/152,306 filed Sep. 3, 1999, which is incorporated herein in its entirety by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates to a modular processing device and a method of use. More particularly, the present invention relates to a modular cooking device and a method of use. 
     BACKGROUND OF THE INVENTION 
     In various situations it is necessary to process objects of different sizes or composition. The nature of the objects often affects the conditions under which the items are processed. It is often desirable to process objects having different sizes or compositions simultaneously or sequentially. 
     For example, when cooking food items such as pizza, it is desirable to use a single oven to cook pizzas having a variety of sizes. It is also desirable to cook pizzas having a variety of dough configurations, such as thin crust, thick crust and stuffed, in a single oven. However, each pizza size and dough configuration requires individual cooking parameters to provide the cooked product with optimal characteristics. 
     In light of the foregoing, it is necessary for a person putting the pizza into the oven to enter the specific cooking parameters into the oven as each pizza is placed in the oven. It can be appreciated that errors can occur in such a process, and an operator can inadvertently enter the wrong parameters. When this happens the pizza emerges from the cooking process undercooked or overcooked thereby requiring the defectively cooked pizza to be discarded. Another pizza must then be prepared and cooked. Delays associated with these errors frequently lead to customer complaints because of the increased waiting time between ordering the pizza and being able to consume the pizza. 
     SUMMARY OF THE INVENTION 
     An embodiment of the present invention relates to a multi-technology oven for processing an item. The multi-technology oven has a plurality of processing modules mounted therein. The plurality of processing modules is removably mounted in the multi-technology oven. The individual modules are operable alone or as a group comprising more than one of the processing modules. 
     Another embodiment of the present invention relates to a method of processing items. The method includes providing a processing device having an entry port and an exit port. A plurality of processing modules is removably mounted in the processing device. The items are moved through the processing device from the entry port to the exit port. The operation of the plurality of processing modules is controlled at selected locations to affect processing of the items. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a top view of a modular oven or other environmental device according to an embodiment of the present invention; 
     FIG. 2 is a schematic view of an oven or other environmental device illustrated in FIG. 1; 
     FIG. 3 is a top view of an oven or other environmental device according to another embodiment of the present invention; and 
     FIG. 4 is a top view of an oven or other environmental device according to yet another embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The present invention is directed to a modular processing device, as illustrated at  10  in FIGS. 1 and 2. The modular processing device  10  has an enclosure  12  in which is mounted a plurality of processing modules  14 . The plurality of processing modules  14  is preferably arranged in an array. 
     The modular processing device  10  of the present invention thereby enables items P having varying characteristics to be processed under individualized conditions such that each type of item P exhibits optimal results from the processing. The processing modules  14  are individually controlled to enable the environment or custom condition created by the processing modules  14  to move with the items P as the items P move through the modular processing device  10 . The modular processing device  10  also detects the type of item P being processed so that the modular processing device  10  can automatically adjust the processing conditions for the particular item P being processed. 
     Examples of processing modules  14  that are suitable for use with the modular processing device  10  of the present invention employ technologies such as air or gas impingement, heat or cold treatment, electronic dielectric heating, microwave, radio wave, ultrasonic wave, light wave, conductive heat, radiant heat, convective heat, cold plate and/or other heating and/or cooling technologies. The plurality of processing modules  14  is preferably used for thermally treating a food product P that is placed in the modular processing device  10 . 
     The processing modules  14  preferably each have a size that is substantially similar so that the processing modules  14  will all fit in a given location. Alternatively, the processing modules  14  may be formed in a size that is equal to an integer times a base unit size. For example, two processing modules  14  of one type are the same size as one processing module  14  of another type. 
     The processing modules  14  are preferably removably mounted in the modular processing device  10  so that the processing modules  14  may be changed to further enhance the flexibility of the modular processing device  10  of the present invention. The processing modules  14  may preferably be swapped while the modular processing device  10  is at least partially activated. Such a procedure is typically referred to as a “hot swap.” Alternatively, the modular processing device  10  is turned off or deactivated prior to changing the processing modules  14 . 
     The processing modules  14  in this preferred embodiment are preferably arranged in four groups that are designated as A, B, C, and D. The processing modules  14  are preferably arranged so that as the items P are moved along a processing direction  16 , the items P encounter one or more of the different types of the processing modules  14 . For example, the items P first pass through processing module A, then two processing modules B, then one processing module D, then one processing module C, and then one processing module D. 
     If the modular processing device  10  has a sufficiently large width such that more than one processing module  14  is needed to extend across the width of the modular processing device  10 , then each of the processing modules  14  that extend across a given width are preferably the same type of processing module  14 . For example, two processing modules C are placed adjacent to each other to extend across the width of the modular processing device  10 . 
     The modular processing device  10  preferably includes a conveyor  20  or other similar device for conveying the items P through the modular processing device  10 . In such a configuration, the modular processing device  10  preferably has an entry region  22  where the items P are placed onto the conveyor  20  prior to being passed through the region of the modular processing device  10  with the processing modules  14 . The modular processing device  10  also preferably has an exit region  24  where the items P that have exited from the region of the modular processing device  10  with the processing modules  14  can be retrieved. 
     The enclosure  12  preferably substantially encloses the region of the modular processing device  10  where the processing modules  14  are located. The enclosure  12  thereby enhances the efficiency of the processing operation and also prevents operators from accidentally contacting potentially hazardous areas of the processing modules  14 . 
     The enclosure  12  also preferably has insulation that at least partially covers an inner surface or an outer surface thereof to enhance the efficiency of the processing operation and reduce the potential for operators from suffering injuries from contacting the enclosure  12 . 
     The enclosure  12  has an entry port  30  that is located between the entry region  22  and the processing modules  14 . The enclosure  12  also has an exit port  32  that is located between the exit region  24  and the processing modules  14 . Depending on the type of processing modules  14  used in the modular processing apparatus, the entry port  30  and/or the exit port  32  may have a door  34  that at least partially closes the entry port  30  and/or the exit port  32 . For example, the door  34  can prevent radiation associated with microwave heating elements from escaping from the enclosure  12 . 
     In the entry region  22  proximate the entry port  30 , the modular processing device  10  preferably includes a sensor  40  that senses the type of item P that is being fed into the modular processing device  10 . In a first configuration, the sensor  40  reads a unique indicia  42  that is imprinted on the item P being fed into the modular processing device  10 . Examples of suitable indicia are bar codes, portable data files or the like. A person of ordinary skill in the art will appreciate that a variety of different technologies are suitable for use in sensing the size or indicia associated with the item P. In an alternative configuration, the senor  40  measures a size of the item P and then operably controls the operation of the processing modules  14  based upon the measured width. 
     The moeular processing device  10  has a control system  50  that receives input from the sensor  40 . Based on this input, the control system  50  operably adjusts the modules controllers  52 ,  54 . The control system  50  also preferably controls the rate at which the conveyor system  20  operates. The conveyor system can be operated in a continuous motion, or a stop/start motion. 
     To further enhance the ability to process individual items P, sensors  56  can be included to monitor the surface conditions at selected locations in the modular processing device  10 . The sensors  56  thereby enable the operating parameters of the modular processing device  10  to be varied based upon the actual performance results of the modular processing device  10  when used with actual items P. 
     Each module is controlled, as denoted at, e.g., A′, B′, C′, to a specific environment, e.g., at one or more specific times, by computer controller  50 , enabling an item P to be thermally treated or reactively acted upon. Sensor  40  and/or sensor  56  read and identify item P and feed information to computer controller  50  for appropriate control of modules A, B, C, D. 
     In operation, the item P, such as a pizza, is prepared and placed into a pan that has indicia that identifies characteristics associated with the item P such as the size and food components placed thereon. Alternatively, the item P may itself have identifying indicia. The item P is then placed on the conveyor  20  in the entry region  22 . 
     The conveyor  20  moves the item P towards the entry port  30  where the item P at least partially passes under the sensor  40  where the sensor  40  reads the indicia. This information is transmitted to the control system  50 . Based upon the indicia, the control system  50  sets parameters associated with the various processing modules  14 . The control system  50  also sets the operational parameters of the conveyor. 
     As additional examples, food items or other items P need not move through the oven or other environmental chamber continuously. Start-stop motion is contemplated, as is temporary or permanent stationary treatment (e.g., baking, cooking, cooling, irradiation or other treatment), optionally as controlled by controller  50  or other control device. 
     Embodiments of the invention allow multiple types of items, and multiple sizes of items (e.g., large, medium and small pizzas of different ingredients, consistencies, thicknesses, weights, and other characteristics), requiring or benefiting from substantially different treatment protocols (e.g., baking temperatures, times and/or methods) to be treated in a single treatment device (e.g., a modular oven having removable and replaceable treatment modules). 
     Embodiments of the invention can greatly reduce equipment, labor, operational and other costs for, e.g., a restaurant or other treatment facility in which the invention is used. Other variations and other advantages will be apparent to those of ordinary skill. 
     In an alternative embodiment, the modular processing device  110  includes a series of five processing modules  114  that extend across a width of the modular processing device, as most clearly illustrated in FIG.  3 . Similar to the embodiment illustrated in FIGS. 1 and 2, the modular processing device  110  has an array of processing modules  114  where the processing modules  114  are aligned along a processing direction  116 , with the modules  114  having a variety of processing characteristics. The processing modules  114  aligned perpendicular to the processing direction  116  preferably have the same processing characteristics. 
     This embodiment of the modular processing device  110  permits multiple items P to be simultaneously processed across a width of the modular processing device  110 . For example, when the indicia associated with a small item P″ sensed by the sensors  140 , the processing modules  114  are sequentially adjusted so that conditions needed to optimally process small item P″ are provided as the small item P″ passes through the modular processing device  110 , such as is illustrated by C″. Similarly, when indicia associated with a large item P″ is sensed by the sensors  140 , the processing modules  114  are sequentially adjusted so that conditions needed to optimally process the large item P′ are provided as the large item P′ passes through the modular processing device  110 , such as is illustrated by B′ and C′. 
     The modular processing device  110  of the present invention thereby enhances the efficiency of the process technique because only the processing modules  114  needed at a particular point are activated. This process thereby allows unneeded processing modules  114  to be turned off. 
     In yet another embodiment, the modular processing device  210  has a stationary operation mode, as most clearly illustrated in FIG.  4 . Similar to the embodiments illustrated in FIGS. 1-3, the modular processing device  210  includes a plurality of processing modules  214  that are arranged in an array within an enclosure  212 . 
     In this embodiment, all of the processing modules  214  preferably have the same mode of operation. Each of the processing modules  214  used in this embodiment have a sensor  256  that monitors the surface conditions proximate that processing modules  214  and report the monitored conditions to a control system (not shown) so that the processing conditions may be adjusted to produce optimal processing results. 
     The modular processing device  210  has a single door  234  that is pivotally mounted to the enclosure  212  for movement between open and closed positions for placing items into and removing items from the modular processing device  210 . The door  234  is preferably closed during the processing operation to enhance the efficiency of the processing operation and reduce the potential for operators suffering injuries associated with contact with or transmission from the processing modules  214  during the processing operation. 
     While the present invention has been described and illustrated with reference to particular embodiments, the invention is not limited to the specific features and examples given. For example, baking, freezing or drying or other treatment of products other than pizzas or food items, such as drying paper, may benefit from the devices and methods disclosed herein. Additionally, combinations of the specified embodiments of the invention may be utilized to increase the advantages of the particular embodiments in any appropriate manner. 
     More specifically, the embodiments shown and described with respect to any one figure can be used with and/or combined with the embodiments of any one or more additional figures. Various other modifications to the invention will occur to those of ordinary skill in the art, and other embodiments and modifications can be made by those skilled in the art without departing from the spirit and scope of the invention.