Abstract:
The present invention is a method for cutting pork to create a meat cut that mimics a pork chop meat. The method involves removing the bone and meat from the pork leg. The method then includes sealing the pork chop within a hermetic enclosure and chilling the enclosed pork chop to a temperature in the range of 35 to 38 degrees Fahrenheit. The resulting meat cut includes, bones or no bones pork chops.

Description:
RELATED APPLICATIONS 
       [0001]    The current application claim the benefit of U.S. Provisional application 61/689,781 filed on Jun. 13, 2012. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT 
       [0002]    N/A 
       BACKGROUND OF THE DISCLOSURE 
       [0003]    1. Field of the Disclosure 
         [0004]    The present invention generally relates to a method for forming a meat cut from a pork leg. In particular, the present invention relates to a method for forming a bone or boneless meat cut to create a final meat product that mimics a pork chops meat which includes pork skin and pork leg meat. 
         [0005]    2. Discussion of the Background 
         [0006]    In recent years, individuals have become increasingly interested in food products that are economical and attractive. There exist in the art methods to produce pork loin back ribs. Such examples produce a meat product that includes both bones and meat or a product made from restructured pork. A meat cut that includes both bones and meat makes it more difficult for a person to consume all available meat because the person must work around and between the bones. In addition, there exist in the art examples of methods for forming a meat cut from a center cut boneless pork loin. Such examples disclose a method that results in a boneless pork loin roast or a pork chop. 
         [0007]    The present invention discloses a more efficient use of available meat on the pork leg. Also, the present invention discloses how to convert a pork leg cut to a more attractive and economically beneficial meat cut to achieve an end product that is more in demand. 
       SUMMARY 
       [0008]    The present disclosure overcomes the limitations of the previous systems and methods for producing pork chops. Accordingly, it is an object of the present disclosure to provide a meat cut that mimics a pork chop meat, wherein the method involves removing the bone, fat, skin and meat from the pork leg. Further, uniformly treating and marinating the meat. The method then includes sealing the pork chop within a hermetic enclosure and chilling the enclosed pork chop. 
         [0009]    It is another object of the present disclosure to provide a meat product that resembles a natural cut of flavored meat, more particularly a pork chop comprising meat, fat, skin and bones. 
         [0010]    Another object of this disclosure is to provide a process for pork chops having reproducible uniformity as to permit its use in restaurants. 
         [0011]    Further, another object of this disclosure is to provide a process for pork chops having reproducible uniformity as to permit its use in restaurants. 
         [0012]    The disclosure itself, both as to its configuration and its mode of operation will be best understood, and additional objects and advantages thereof will become apparent, by the following detailed description of a preferred embodiment taken in conjunction with the accompanying drawings. 
         [0013]    The Applicant hereby asserts, that the disclosure of the present application may include more than one invention, and, in the event that there is more than one invention, that these inventions may be patentable and non-obvious one with respect to the other. 
         [0014]    Further, the purpose of the accompanying abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the disclosure of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the disclosure in any way. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    The accompanying drawings, which are incorporated herein, constitute part of the specification and illustrate the preferred embodiment of the disclosure. 
           [0016]      FIG. 1  shows a general structure of the pork leg in accordance with the principles of the present disclosure. 
           [0017]      FIG. 2  shows side view of the pork leg in accordance with the principles of the present disclosure. 
           [0018]      FIG. 3  shows an inner structure of the pork leg in accordance with the principles of the present disclosure. 
           [0019]      FIG. 4 . shows an exemplary embodiment of the process for removing pork leg skin and bones in accordance with the principles of the present disclosure. 
           [0020]      FIG. 5A-5G . shows an exemplary embodiment of the process for removing pork leg skin and bones using a programmable machine in accordance with the principles of the present disclosure. 
           [0021]      FIG. 6A-6D  shows an exemplary embodiment of pork meat assembling in accordance with the principles of the present disclosure. 
           [0022]      FIG. 7 . shows an exemplary embodiment of the pork chop mold product in accordance with the principles of the present disclosure. 
           [0023]      FIGS. 8A-8B . shows an exemplary embodiment of the pork chop mold main body in accordance with the principles of the present disclosure. 
           [0024]      FIGS. 9A-9B . shows an exemplary embodiment of the pork chop mold top body in accordance with the principles of the present disclosure. 
           [0025]      FIGS. 10A-10B . shows an exemplary embodiment of the pork chop mold center body in accordance with the principles of the present disclosure. 
           [0026]      FIG. 11 . shows an exemplary assembling for the pork chop mold center body and top body in accordance with the principles of the present disclosure. 
           [0027]      FIG. 12 . shows an exploded view of the attachment mean for the pork chop mold main body and top body in accordance with the principles of the present disclosure. 
           [0028]      FIG. 13A-13F . shows a first exemplary embodiment of the pork chop product in accordance with the principles of the present disclosure. 
           [0029]      FIG. 14A-14D . shows a second exemplary embodiment of the pork chop product in accordance with the principles of the present disclosure. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0030]    Referring to  FIG. 1 , discloses a pork leg  1 , wherein said pork leg  1  comprises bones B, skin S, fat F and meat M. Usually a knife  2  is used for removing the bones, skin, fat and meat of the pork leg  1 . The pork leg is surrounded by skin S, as shown in  FIG. 2  covering the bones, fat and meat. Therefore in order to remove the meat, bone and fat the skin has to be cut of and removed. 
         [0031]    Further, as shown in  FIG. 3 , the pork leg  1  comprises several bones ( 3 , 4 , 5 , 6 , 7 ) that need to be removed. The followings are: aitch bone  3 , leg bone  4 , knee cap  5 , stifle joint  6  and hind shank bones  7 . 
         [0032]    As mentioned above, the skin S is cut off and hooks  8  are used to open or created enough space to remove the bones B, as show in  FIG. 4 . The process is performed at a temperature in the range of 32 to 33 degrees Fahrenheit. Even when the process can be performed by an employed the present invention presents the option of using an automatic procedure wherein said skin, fat, bones and meat is removed by a programmable machine  100 . 
         [0033]      FIG. 5A through 5G  are directed to the programmable machine  100 . The programmable machine  100  comprises a frame  1000 , a table assembly  104 , a holder section  101 , grasping element  103  and programmable cutter  102 . 
         [0034]    During the process of removing the bones from the pork leg  1 , said pork leg  1  is positioned on top of table  104 , wherein a holder section  101  avoids the unwanted horizontal displacement. The holder  101  is also capable of providing rotation upon the pork leg  1  on the horizontal axis, more particularly assisting the extraction of the bones. The holder comprises at least an actuator  1010 , pressing means  1011  and a cutter. The cutter as shown in  FIG. 5C  comprises a saw motor  1012  and saw blades  1013 . The wherein said pressing means  1011  are activated by the actuator  1010  in order to compress the pork leg  1  at a distal end. The pressing mean  1011  hold the pork leg  1  through the process of extracting bones. 
         [0035]    The programmable cutter  102 , as shown in  FIG. 5D , is provided with a set of instructions in order to cut through the skin, based on several coordinates, and around the bones. The programmable cutter  102  comprises a base  1024 , a blade  1020 , a blade actuator  1021 , pivot element  1023  and extendable arm  1022 . The extendable arm  1022  is attached to the pivot element  1023  at a distal end, while the other distal end supports the blade actuator  1021 . The extendable arm  1022  pivots around the pivot element  1023 . The blade actuator  1021  holds the blade  1020  and generates the movement of the blade. The blade actuator  1021 , extendable arm  1022  and base  1024  movement depend on the set of instructions. 
         [0036]    Further ones the meat is separated from the bones by means of the programmable cutter  102  a grasping element  103  removes the bones. The grasping element, as shown in  FIG. 5E , comprises at least a clamp  1033 , a clamp actuator  1032 , vertical trail  1031  and horizontal tray  1030 . The clamp  1033 , which is activated by the clamp actuator  1032 , moves through vertical trail  1031  and horizontal trail  1030  by means of a linear motor and/or rotational motor in order to position the clamp closer to the bone to be removed. 
         [0037]      FIG. 5F  is directed to the table assembly  104 . The table assembly  104  comprises at least a table trail  1041 , a hook  1042  and a table  1040 . The hook  1042  holds the pork leg  1  on top of the table  1040 , while the table trail  1041  provides enough area for the displacement of the pork leg during the process of removing the bones. The table  1040  moves on top of the table trail  1041  by means of a linear motor and/or rotational motor in order to position the clamp closer.  FIG. 5G  is more directed to the system with the frame, wherein the programmable cutter  102  are located on top of supporter  1001 . The table trail  1041  and  101  holder section  101  are adjusted to the frame  1001 . 
         [0038]    The programmable machine  100  may comprise more than one programmable cutter  102  in order to remove bones. A conveyer (not show) is located under the table  104  in order to transport the skin, fat and meat to a flavor addition process after the bones are removed. The table  104  is tilted, after the bones are removed, to push the residual the skin, fat and meat to the conveyer. After the injection of flavors the conveyer directs the skin, fat and meat to a process wherein the skin, fat and meat might be separated. 
         [0039]    As mentioned, the skin, fat and meat is injected with flavors or marinated with a uniform compound assisting to create a meat product, such as pork chop, having reproducible uniformity as to permit its use in restaurants. Further the uniform compound which comprises several natural spices assist with killing germs and/or bacteria. 
         [0040]    Further the removed skin, bones, fat and meat are sealed within a hermetic enclosure or mold  20 .  FIG. 6A through 6D  are directed to the process of encapsulating the skin, bones, fat and meat in a mold  20 . 
         [0041]    The mold  20 , as shown in  FIG. 7 , comprises a main hollow body  23 , a center body  22  and a top body  21 . Basically, the main body  23  is configured to provide a pork chop shape comprises an opening, as shown in  FIG. 8A and 8B , and serves as the base for the mold  20 . 
         [0042]    Further a top section  21 , in combination with center body  22 , is provided to close the opening of the main body  23 . The top body  21  and center body  22  are configured to cover the opening of the main body  23 , while maintaining the shape of the pork chop, as shown in  FIG. 9A through 10B . 
         [0043]    In order to close and seal the main body with the skin, bones, fat and meat inside the mold  20  the top body, having a hook alike shape as shown in  FIG. 9A , is positioned on top of the center body  22 , having a S-like shape as shown in  FIG. 10A , in such way that firmly hold the center body in position. Further attaching means  211  are connected with receiving means  231 , as shown in  FIG. 7  and  FIG. 12 . Once the top  21  and center body  22  are positioned closing the main body  23  opening the attaching and receiving means provide enough pressure to close and seal the skin, bones, fat and meat inside the mold  20 . The mold is then chilled at a temperature in the range of 35 to 38 degrees Fahrenheit. 
         [0044]    The result is a meat product P comprising skin, fat, bone and meat.  FIG. 13A through 13F  provide different configuration for a meat product P that mimics a pork chop comprising skin S, fat F, bone B and meat M in accordance with the present invention.  FIG. 14A through 14F  is more directed to a meat product that mimics rounded piece of meat. Adding bones or making the meat product P might depend on the clients specifications or preferences. Since the bones, meat, fat and skin are added by preference different combinations can be provided. For example the pork chop can be bone or boneless, the skin and fat can cover part of the meat or be around the meat. Independently of the shape the flavor of the meat product is constant and provide substantially the same size, therefore the cooking time at the restaurant might be constant if cooking conditions are the same. 
         [0045]    The exemplary embodiment, more particularly the meat product P, provide the use of a pork leg  1 , however other animal parts can be used. Further, the process may be repeated independently from the type of prime material, such as meat, being used. For example the process is as follow:
       1. Provide the prime material. In the instant case the prime material comprises any type of meat, fish, seafood, fruits, vegetables or any combination.   2. Removed bones when needed. The process to remove bone where previously describe. The use of an automatic machine reduces man power and time. It is important to understand the step to removed bones from meat can be completed for any part of an animal. The average temperature during this process is in the range of 32 to 33 degrees Fahrenheit.   3. Add flavor or marinate the prime material   4. Extract proteins. The skin and meat are exposed to the extraction of proteins individually or in combination. In the instant case proteins are removed by a vibration procedure which reduces the time for extracting proteins. The average temperature during the extraction of proteins is in the range of 34 to 35 degrees Fahrenheit.   5. Sealing the prime material within a hermetic enclosure or mold. The mold is configured to mimic or resemble a natural cut.   6. Chilling the enclosed prime material at a temperature in the range of 35 to 38 degrees Fahrenheit.   7. Cook prime material inside the mold. The meat is cook for approximately 2 hours as a temperature of 130 degrees Fahrenheit. Further the temperature is raised up to 150 degrees Fahrenheit for a period of approximately 2 hours. Again the temperature is raised up to 160 degrees Fahrenheit for a final period until the mold reaches an internal temperature of 140 degrees Fahrenheit.   8. Chill the cooked and molded prime material inside the mold. The prime material is cooled down for a period of 6 hour until reaching 33 degrees Fahrenheit. Further the molded prime material is cooled down for another 6 hours until reaching 0 degrees Fahrenheit. The temperature inside the mold starts at 140 degrees Fahrenheit and ends up at 0 degrees Fahrenheit.   9. Cut in slices. If the mold dimensions are big enough the molded prime material is divided into prime material slices for individual services.   10. The sliced prime material is packed or wrapped in plastic preferable in a vacuum space.       
 
         [0056]    The disclosure is not limited to the precise configuration described above. While the disclosure has been described as having a preferred design, it is understood that many changes, modifications, variations and other uses and applications of the subject disclosure will, however, become apparent to those skilled in the art without materially departing from the novel teachings and advantages of this disclosure after considering this specification together with the accompanying drawings. Accordingly, all such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the disclosure are deemed to be covered by this disclosure as defined in the following claims and their legal equivalents. In the claims, means-plus-function clauses, if any, are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. 
         [0057]    All of the patents, patent applications, and publications recited herein, and in the Declaration attached hereto, if any, are hereby incorporated by reference as if set forth in their entirety herein. All, or substantially all, the components disclosed in such patents may be used in the embodiments of the present disclosure, as well as equivalents thereof. The details in the patents, patent applications, and publications incorporated by reference herein may be considered to be incorporable at applicant&#39;s option, into the claims during prosecution as further limitations in the claims to patently distinguish any amended claims from any applied prior art.