Abstract:
A method and apparatus for withdrawing a sleeve with sandwich fixings therein from an opening in a bread bun while resisting the sandwich fixings from exiting the bun includes a holding area with a longitudinal axis to receive a sandwich with a sleeve therein. A gripper is disposed with respect to the holding area to selectively grasp the sleeve when the sandwich is in the holding area. The gripper can include a hook extendable through a hole in the sleeve. A stopper is associated with the holding area and positionable at the opening in the bread bun and at one end of the sleeve. The gripper and the holding area with the stopper are displaceable with respect to one another along the longitudinal axis to withdraw the sleeve from the bread bun.

Description:
[0001]    This application is a continuation-in-part application of U.S. patent application Ser. No. 10/607,844, filed Jun. 27, 2003; which is a divisional application of U.S. Pat. No. 6,599,545, issued Jul. 29, 2003, and filed Jul. 26, 2000, as U.S. patent application Ser. No. 09/626,199. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. The Field of the Invention  
           [0003]    The present invention relates generally to a method and apparatus for making a sandwich. More particularly, the present invention relates to a method and apparatus for withdrawing a sleeve with sandwich fixings therein from an opening in a bread bun while resisting the sandwich fixings from exiting the bun.  
           [0004]    2. The Background Art  
           [0005]    Sandwiches are a popular food item enjoyed by many people of various ages. The main feature of many lunches is a sandwich. Sandwiches typically comprise two slices of bread, and a combination of sandwich fixings disposed between the bread slices. Such sandwiches may be “cold” or “hot.” Cold sandwiches often include items such as cold cuts, while hot sandwiches may be entirely heated, or include a heated item, such as meat balls. Many sandwiches are made at home, or purchased from specialty sandwich shops.  
           [0006]    Although sandwiches may have innumerable combinations of bread types and fixing types, many people share common requirements of their sandwich. For example, it is often desirable that the sandwich be fresh, or have fresh bread and fresh fixings. In addition, it is often desirable that the sandwich be made fresh. While it is common for a sandwich to be pre-prepared, such as by making the sandwich in the morning, the fixings tend to seep into the bread, making the bread soggy and undesirable.  
           [0007]    Another common prerequisite for sandwiches is that the sandwich stay together, or maintain its structural integrity. It will be appreciated that the contents of the sandwich often become separated from the bread while the sandwich is being eaten, often resulting in lost, inedible food, and/or messy clothes or eating area.  
           [0008]    Some efforts have been directed towards improving sandwiches, such as by sealing the contents of the sandwich in the bread, and providing baked shells, examples of which may be found in U.S. Pat. Nos. 6,004,596 and 5,567,445. It is believed that the baked shells lack popularity due to the large amount of crust, both on the outside and inside, that is produced. In addition, it is believed that sealing sandwich contents in the bread is only feasible for particular types of sandwich fixings which prevent moisture from reaching the bread, such as peanut butter. Despite these efforts, the vast majority of sandwiches are produced, both at home and commercially, with the traditional contents “sandwiched” between two slices of bread.  
           [0009]    Other food items have been developed, which are similar in many respects to sandwiches, and which may have been developed to address the drawbacks of typical sandwiches. For example, pocket-type food items have a layer of dough wrapped about a meat substance and baked or cooked. Some examples are shown in U.S. Pat. Nos. 5,622,742; 5,780,082; and 4,888,192. It is believed that such types of food are limited to baked or cooked food, and are ill suited for many sandwiches, such as cold cuts. In addition, it is believed that such pocket-type food items are unsuitable for typical sandwiches because the outer, dough layer has a crust consistency, and lacks a bread-like consistency.  
           [0010]    Still other food types include injecting one food substance into another. For example, a jelly or cream may be injected into a donut or bagel. Examples of injecting are described in U.S. Pat. Nos. 5,900,265 and 5,641,527. Still other food types include extruding one or more food substances. Examples of extruding food are described in U.S. Pat. Nos. 5,194,283 and 4,888,192. It is believed that injection and extrusion methods are unsuitable for traditional sandwiches.  
         SUMMARY OF THE INVENTION  
         [0011]    It has been recognized that it would be advantageous to develop a sandwich with traditional texture and consistency, but without traditional messiness. In addition, it has been recognized that it would be advantageous to develop a method for making such a sandwich.  
           [0012]    The invention provides a device to withdraw a sleeve with sandwich fixings therein from an opening in a bread bun while resisting the sandwich fixings from exiting the bun. The device includes a holding area with a longitudinal axis to receive a sandwich with a sleeve therein. A gripper is disposed with respect to the holding area to selectively grasp the sleeve when the sandwich is in the holding area. A stopper is associated with the holding area, and positionable at the opening in the bread bun and at one end of the sleeve. The gripper and the holding area with the stopper are displaceable with respect to one another along the longitudinal axis to withdraw the sleeve from the bread bun.  
           [0013]    In accordance with a more detailed aspect of the present invention, the gripper can include a hook to extend through a hole in the sleeve.  
           [0014]    In accordance with a more detailed aspect of the present invention, the device can include a carriage slidably disposed on at least one rail, with the gripper being attached to the carriage.  
           [0015]    In accordance with a more detailed aspect of the present invention, the device can include an elongated rod disposed parallel with the longitudinal axis, with the stopper being disposed on an end of the rod.  
           [0016]    The invention also provides a method for withdrawing a sleeve with sandwich fixings therein from an opening in a bread bun while resisting the sandwich fixings from exiting the bun. The method includes positioning a stopper at the opening in the bread bun and at one end of the sleeve. The end of the sleeve is grasped with a gripper. The gripper is displaced, along with the sleeve, with respect to the bread bun. The stopper is maintained relative to the bread bun so that the sandwich fixings abut the stopper as the sleeve is withdrawn to resist the sandwich fixings from exiting the bun.  
           [0017]    Additional features and advantages of the invention will be set forth in the detailed description which follows, taken in conjunction with the accompanying drawing, which together illustrate by way of example, the features of the invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]    [0018]FIGS. 1-4 are perspective views of a method of making a sandwich (FIG. 4), or inserting a first, filler-type foodstuff or sandwich fixings (FIG. 3) into a second, shell-type foodstuff or bread bun (FIGS. 1 and 2), in accordance with the present invention;  
         [0019]    [0019]FIGS. 5-10 are perspective views further illustrating the method shown in FIGS. 1-4, or inserting the first foodstuff or sandwich fixings into the second foodstuff or bread bun, using a flexible sheet (FIG. 5) or carrier in accordance with the present invention;  
         [0020]    [0020]FIGS. 11 and 12 are perspective views further illustrating the method shown in FIGS. 1-4, or forming a cavity and opening in the second foodstuff or bread bun using an elongated cylindrical drill bit, in accordance with the present invention;  
         [0021]    [0021]FIGS. 13-15 are perspective views of a device for withdrawing a sleeve with sandwich fixings therein from an opening in a bread bun while resisting the sandwich fixings from exiting the bun in accordance with an embodiment of the present invention;  
         [0022]    [0022]FIG. 16 is a perspective view of a device for withdrawing a sleeve with sandwich fixings therein from an opening in a bread bun while resisting the sandwich fixings from exiting the bun in accordance with an embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0023]    For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the invention as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.  
         [0024]    A method is illustrated in the Figures for inserting a first, filler-type foodstuff into a second, shell-type foodstuff in accordance with the present invention which is particularly well suited for making sandwiches. The term “foodstuff” is used broadly herein to refer to edible substances, including for example, bread, buns, meat, cheese, fruits, vegetables, tomatoes, lettuce, onions, condiments, etc. The term “filler-type foodstuff” is used broadly herein to refer to any type of edible substance that is disposed in or on another, including for example, sandwich fixings, etc.; while the term “shell-type foodstuff” is used broadly herein to refer to any type of edible substance that is disposed around another, including for example, bread, buns, etc.  
         [0025]    Sandwiches and sandwich making may be a field which may benefit from use of such a method. Thus, the method of the present invention will be described with particular reference to sandwiches and sandwich making. By way of example, the method of the present invention is illustrated in making a sandwich, indicated generally at  10  in FIG. 4, where the first foodstuff includes sandwich fixings, indicated generally at  18  in FIG. 3, and the second foodstuff is a bread bun, indicated generally at  14  in FIGS. 1 and 2. The term “bread bun” is used broadly herein to refer to any type of bun or bread, including for example, a hoagie bun; while the term “sandwich fixings” is used broadly herein to refer to any type of sandwich ingredient or component, including sliced meat, sliced cheese, sliced tomatoes, sliced onions, shredded lettuce, sliced pickles, olives, mayonnaise, vinegar, mustard, salt and pepper, etc.  
         [0026]    Referring to FIG. 1, a bread bun  14  is provided, which may be an elongated, hoagie-type bun, as shown, with a longitudinal axis  20 . The bread bun  14  preferably is pre-baked to have an outer or exterior crust  22  and a substantially filled, fleshy interior. The exterior crust  22  may be harder than the softer, fleshy interior. Referring to FIG. 2, a cavity  24  is formed in the bread bun  14 , and an opening  26  is formed through the crust  22  to the cavity  24 . The cavity  24  preferably is elongated and extends substantially the length of the bread bun  14 . In addition, the cavity  24  preferably is formed without a crust, or with an inner or interior surface  28  which is the same as the fleshy interior of the bread bun  14 , so that the bread bun  14  maintains a more sandwich-like structure and consistency. Alternatively, the cavity  24  may be pre-formed in the bread-bun  14 , such as by being baked in, although such a process may create an interior surface which also is a crust, and thus give the bread bun a more crusty texture and consistency.  
         [0027]    The cavity  24  in the bread bun  14  advantageously forms a hollowed bread bun with a unitary or integral shell formed of a substantially continuous wall of bread. Thus, unlike traditional sandwiches, the bread bun  14  with a cavity  24  forms a pocket with the breaded side walls resisting any contents of the cavity  24  from escaping. In addition, the bread bun  14  retains its bread-like consistency and structure, which is familiar and enjoyable, without presenting a hard crusty, or thin doughy, layer.  
         [0028]    Referring to FIG. 3, the sandwich fixings  18  are prepared for being inserted into the cavity  24  of the bread bun  14 . As stated above, the sandwich fixings  18  may include sliced meat  30 , sliced cheese  32 , fruits and/or vegetables, such as sliced tomatoes  36  and lettuce  38 , etc. In addition, the sandwich fixings  18  may include condiments, such as mustard  40  and mayonnaise  42 . All of the sandwich fixings  18  may be provided in layers. Referring to FIG. 4, the sandwich fixings  18  advantageously are inserted through the opening  26  in the exterior crust  22  and into the cavity  24  of the bread bun  14 , indicated by arrow  44 , to form the sandwich  10 . The fixings  18  preferably are inserted together to maintain the freshness and dryness of the bread bun  14 . In addition, the sandwich  10  preferably is prepared immediately prior to consumption to further resist the bread bun  14  from becoming overly moist from the fixings  18 .  
         [0029]    As stated above, the fixings  18  preferably are inserted together. The fixings  18  advantageously can be inserted into the cavity  24  utilizing a carrier. The carrier advantageously maintains the sandwich fixings  18  together, and provides a rigidity or structure to facilitate insertion. It will be appreciated that some fixings  18  may be loose and flexible, especially when combined together. In addition, it will be appreciated that the fixings  18 , when assembled, may be larger than the opening  26  in the crust  22  or bread bun  14 . Thus, the carrier can hold the fixings  18  together, and present the fixings  18  in a size similar to the opening  26 .  
         [0030]    Referring to FIG. 5, the carrier can be a flexible sheet  50  of material, such as food grade plastic, which is flexible enough to be bent, and provides a low friction surface  52 . The sheet preferably has a length L substantially equal to or greater than the length of the cavity  24  or bread bun  14 , and a width equal to, or greater than, the circumference of the opening  26  in the bread bun  14 . Referring to FIG. 6, the sandwich fixings  18  can be placed onto the surface  52  of the flexible sheet  50 . In addition, the fixings  18  may be arranged on the sheet  50  in a similar fashion as they might be placed onto a traditional sandwich, such that the sheet  50  acts as a pseudo slice of bread. Thus, the fixings  18  may be arranged in layers on sheet  50 .  
         [0031]    Referring to FIG. 7, the flexible sheet  50 , with the sandwich fixings  18  thereon, may be rolled together, as indicated by arrows  56 , into a cylindrical, tubular sleeve  60  with the fixings  18  therein. Many types of fixings  18 , such as sliced meat and cheese, can be flexible, and can roll into arcuate layers within the sleeve  60 . Preferably, the sheet  50  is rolled into a sleeve  60  with a diameter D equal to, or less than, a diameter of the opening  26  in the bread bun  14 . Although the sheet  50  is flexible, rolling the sheet  50  into the sleeve  60  advantageously provides rigidity. The sleeve  60  has a longitudinal axis  62 .  
         [0032]    Referring to FIG. 9, the sleeve  60 , with the sandwich fixings  18  therein, can be inserted through the opening  26  of the bread bun  14 , and into the cavity  24 , indicated by arrow  64 . Preferably, the sleeve  60  is inserted the entire length of the cavity  24 . As stated above, the sleeve  60  provides rigidity for inserting the sleeve  60  into the cavity  24  of the bread bun  14 .  
         [0033]    Referring to FIG. 10, the sleeve  60  then can be withdrawn from the cavity  24 , indicated by arrow  66 , while leaving the fixings  18  within the cavity  24  to form the sandwich  10 . It may be necessary to resist the fixings  18  from exiting the cavity  24  with the sleeve  60 . As stated above, the sheet  50  preferably has a low friction surface  52 , so that the inner surface of the sleeve  60  also has low friction, to facilitate sliding the fixings  18  out of the sleeve  60  and into the cavity  24 .  
         [0034]    Referring to FIGS. 11 and 12, a drilling device  70  is shown for forming the cavity  24  in the bread bun  14 . The drilling device  70  advantageously has an elongated, hollow, cylindrical drill bit  72  rotatably driven by a motor  74 . The motor  74  may be movably disposed on a base  76 . The drill bit  72  preferably has an open end  78  with a serrated edge  80  for cutting. A holding enclosure  82  can also be disposed on the base  76  for receiving and holding the bread bun  14 . The holding enclosure  82  orients and maintains the longitudinal axis  20  of the bread bun  14  aligned with, or concentric with, a longitudinal axis  84  of the drill bit  72 . An indentation  86  may be formed in the holding enclosure  82  for receiving the bread bun  14 . A lid or restraint  88  may be pivotally coupled to secure the bread bun  14  in the indentation  86 . Preferably, the holding enclosure maintains the bread bun  14  substantially immobile.  
         [0035]    As stated above, the motor  74  and drill bit  72  may be slidably disposed on the base  76 , such as being attached to a carriage  90  slidably disposed on sliders  92  attached to the base  76 . The carriage  90  and sliders  92 , and thus the drill bit  72 , can be aligned to displace along the longitudinal axes  20  and  84 . Referring to FIG. 11, the drill bit  72  may be rotated by the motor  74 , indicated by arrow  94 , and displaced longitudinally, indicated by arrow  96 , so that the drill bit  72  engages and drills into the bread bun  14 . As the drill bit  72  rotates  94  and displaces  96 , the serrated edge  80  cuts a cylindrical hole into the bread bun  14 , leaving the cavity  24 .  
         [0036]    After the drill bit  72  has traveled to the desired depth, preferably just short of the end of the bread bun  14 , the drill bit is withdrawn, as indicated by arrow  98  in FIG. 12. It will be appreciated that the drill bit  72  may leave a cylindrical slug of bread, which may be left in the bread bun  14 , or may be withdrawn with the drill bit  72 . In either event, the bread slug may be pulled from either the drill bit  72  or bread bun  14 . Alternatively, the drill bit  72  may shred or cut the bread in the drill bit, leaving crumbs. The bread bun  14 , with the cavity  24 , then can be removed from the holding enclosure  82 .  
         [0037]    The drilling device  70  may be vertically oriented as shown, much like a drill press. Alternatively, the device  70  may be vertically oriented with the holding closure  82  disposed above the drill bit  72 , opposite as shown, so that crumbs may fall out under the force of gravity.  
         [0038]    Although the drill bit  72  and motor  74  have been described as displacing on the base  126 , it is of course understood that the holding enclosure  82  and bread bun  14  may displace on the base  126  towards the drill bit  72 .  
         [0039]    Referring to FIGS. 13-15, an extraction device  120  is shown for withdrawing the sleeve  60  from the cavity  24  of the bread bun  14  and resisting the fixings  18  from exiting the cavity  24 . The extraction device  120  can include a holding enclosure  122  with an indentation  124  for receiving the bread bun  14  similar to that described above. Again, the holding enclosure  122  may secure and orient the bread bun  14 . A gripping or pinching mechanism  128  may be configured to grip, grasp or pinch the sleeve  60 . For example, the gripping mechanism  128  may have a pair of members  130  and  132  which receive a portion of the sleeve  60  therebetween. The members  130  and  132  may abut one another and be slightly flexible such that the sleeve  60  may be forced therebetween and held.  
         [0040]    The gripping mechanism  128  can be attached to a carriage  136  slidably disposed on slides  138  attached to a base  140 , so that the gripping mechanism  128  is slidably or movably disposed on the base  140  with respect to the bread bun  14  and holding enclosure  122 . The slides  138  and carriage  136  preferably are aligned with the holding enclosure  122  and longitudinal axis  20  of the bread bun  14 .  
         [0041]    A stop or stop member  144  advantageously is disposed on the base  140 , and located adjacent the holding enclosure  122 , such that the stop member  144  is located adjacent the opening  26  of the bread bun  14  when disposed in the holding enclosure  122 . In addition, the stop member  144  can be disposed on the end of an elongated rod oriented parallel with the direction of travel of the gripping mechanism  128 .  
         [0042]    Referring to FIG. 13, the bread bun  14 , with sleeve  60  and fixings  18  therein, can be secured in the holding enclosure  122  with the stop member  144  located adjacent the opening  26  (best seen in FIG. 15) and one end of the sleeve  60 . The gripping mechanism  128  then can be positioned to grip the sleeve  60 .  
         [0043]    Referring to FIG. 15, the gripping mechanism  128  and carriage  136  can be displaced away from the bread bun  14  along the longitudinal direction, indicated by arrow  148 . As the gripping mechanism  128  is displaced, it withdraws the sleeve  60  from the bread bun  14 . Meanwhile, the stop member  144  abuts the fixings  18 , advantageously resisting the fixings  18  from exiting the cavity  24  with the sleeve  60 . As the carriage  136  and gripping mechanism  128  displace  148 , the sleeve  60  is drawn over the stop member  144  and rod  146 . The bread bun  14  or sandwich  14  then may be removed from the holding enclosure  122 .  
         [0044]    Although the gripping mechanism  128  has been described as displacing on the base  140 , it is of course understood that the holding enclosure  122  and stop member  144  may displace on the base  140 .  
         [0045]    Referring to FIG. 16, another extraction device  120   b  is shown for withdrawing the sleeve  60  from the cavity  24  of the bread bun  14  while resisting the fixings  18  from exiting the cavity  24  that is similar to that described above. The extraction device  120   b  can include a gripper  128   b  that can include a hook  128   c  to extend through a hole  128   d  in the sleeve  60 . Thus grasping the end of the sleeve can include engaging the hole in the sleeve with the hook.  
         [0046]    It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present invention. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present invention and the appended claims are intended to cover such modifications and arrangements. Thus, while the present invention has been shown in the drawings and fully described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred embodiment(s) of the invention, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made, without departing from the principles and concepts of the invention as set forth in the claims.