Abstract:
A device and method for heating a food product are disclosed. The device contains a support member for supporting a food product in a first position and a second position, a heating mechanism associated with the support member and positioned to heat the support member when the support member is in the first position and in the second position, and another heating mechanism positioned to heat the food product when the food product is in the second position.

Description:
FIELD 
       [0001]    The present application relates to an apparatus for the manufacture of flat bread and a method of making such flat bread using a device of the type described herein. 
       BACKGROUND 
       [0002]    Flat bread is a bread of Middle Eastern origin dating back a number of centuries. In general, flat bread is relatively thin bread having a generally rounded or oval shape. It may be used as a wrapper to enclose other food making up the meal. 
         [0003]    Brick ovens have been traditionally used for the production of food substances including pizza, flat breads, traditional breads, and the like. Brick ovens fall into a number of categories including: (1) common deck ovens enhanced with a supplemental ceramic, brick, firebrick, stone, baked clay, transite, quarry tile, or other metallic and non-metallic materials which serve as a baking surface (“hearth”) that is placed on the cooking chamber&#39;s floor and sometimes on racks within the cooking chamber; (2) deck ovens designed and manufactured with an incorporated baking chamber floor of a material which serves as a hearth; and (3) custom-built brick ovens which contain a hearth, walls and ceiling of one or more of the above mentioned materials. 
         [0004]    Brick ovens are considered by many production personnel, bakers, operators of restaurants and production equipment, and individuals familiar with the art (“bakers”) to produce a product that is superior to that which can be produced in ovens utilizing a conventional, convection or impingement cooking chamber but lacking a hearth. Most commonly, these ovens employ a primary thermostatically controlled heating means of electricity, natural gas, or propane. In some applications, wood or coal is used. However, temperature within the cooking chamber of a wood or coal fired oven is often difficult to control and preheat times are lengthy. New wood-burning brick ovens, featuring a primary heating means via natural gas, electricity or propane with wood incorporated mainly for its visual appeal, have attempted to remedy this shortcoming. 
         [0005]    There are many reasons why a brick oven produces superior baked food substances. Superior quality is generally attributed to the fact that food substances are placed directly on a pre-heated hearth. The hearth also has a tendency to absorb moisture during the baking process. Although the food substances are subjected to heat from all sides thereby simultaneously baking from all sides, the most intense and rapid heat transfer takes place from beneath due to the direct contact between the pre-heated hearth and the food substance. This degree of heat transfer cannot be achieved in ovens where direct contact with a pre-heated hearth is not possible. 
         [0006]    Other technologies that improve heat transfer include hot air convection cooking and forced hot air impingement, which serve to reduce the cold zone that surrounds food substances. These technologies increase the rate at which heat transfer takes place; however, these technologies still fail to achieve the same rapidity of heat transfer that is achieved via the direct contact with a pre-heated hearth. 
         [0007]    The rapid heat transfer that takes place between a pre-heated hearth and food substances results in a reduced bake time and a baking process that effectively causes food substances to bake from the bottom-up. 
         [0008]    However, bakers who utilize brick ovens report the task of baking food substances in brick ovens is far more labor intensive than baking with a common deck oven, as more training is required to achieve satisfactory results than is necessary with the common deck oven. A number of shortcomings were cited which explain the increased difficulty of operation. 
         [0009]    One such shortcoming is wide fluctuations in hearth temperature. These fluctuations are caused by the placement of food substances directly on the hearth for baking. When a food substance is placed directly on the hearth, the heat transfer that takes place results in a decrease in the temperature of the hearth. When baking is complete and the food substance is removed, the area of the hearth on which baking occurred must be given time to recover its lost energy and return to optimum baking temperature before another food substance can be placed on the same area and baked with a similar result. This is known as recovery time. This recovery process also serves to purge the hearth of any moisture that may have been absorbed during the baking process. In high volume operations, bakers report difficulty remembering which areas of the hearth are in the process of recovery and which areas have recovered to optimum baking temperature. When multiple bakers are involved in production, this process becomes extremely difficult. 
         [0010]    Brick ovens also share the commonly reported shortfall of common deck ovens which is the necessity of having to open the door to the baking chamber repeatedly to check food substances baking on the hearth. Due to the rapid transfer of heat from the hearth to food substances as well as varying hearth and ambient air temperatures within the cooking chamber, bakers must make regular observations to ensure a quality product. This is especially prevalent in high volume operations that utilize brick ovens with multiple bakers involved in the baking process at the same time. Furthermore, the increased frequency of opening the oven door results in greater temperature fluctuations within the cooking chamber. The result of this extensive interaction is inconsistent product quality, decreased energy efficiency, and an uncomfortable, hot work environment. Increased risk of injury also results from the intensive interaction with the oven. Because the process of checking for doneness of food substances is repeated so often, some brick oven manufacturers have eliminated the oven door. Bakers claim the risk of burns is further increased by the lack of a door due to the direct exposure to the interior cooking chamber while energy efficiency is decreased. 
         [0011]    The present disclosure overcomes all of the above discussed problems by providing a method and an apparatus for producing thin, flat bread with the same quality and appeal of a product cooked by a hearth baking process. The present disclosure enables making of such bread in a rapid and convenient manner by even the most unskilled of bakers. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0012]      FIGS. 1   a - b  depict an exemplary embodiment of an apparatus according to present disclosure; 
           [0013]      FIG. 2  depicts another view of the exemplary embodiment of the apparatus according to present disclosure as shown in  FIGS. 1   a - b;    
           [0014]      FIG. 3  depicts another view of the exemplary embodiment of the apparatus according to present disclosure as shown in  FIGS. 1   a - b;    
           [0015]      FIG. 4  depicts an exemplary embodiment of a heating mechanism; 
           [0016]      FIG. 5  depicts another view of the exemplary embodiment of the apparatus according to present disclosure as shown in  FIGS. 1   a - b;    
           [0017]      FIG. 6  depicts another view of the exemplary embodiment of the apparatus according to present disclosure as shown in  FIGS. 1   a - b;    
           [0018]      FIGS. 7   a - d  depict an exemplary embodiment of a nozzle; 
           [0019]      FIGS. 8   a - d  depict an exemplary embodiment of a cover; 
           [0020]      FIG. 9  depicts another exemplary embodiment of an apparatus according to present disclosure; 
           [0021]      FIG. 10  depicts an exemplary embodiment of a heating assembly for the apparatus depicted in  FIG. 9 ; 
           [0022]      FIGS. 11   a - b  depict another exemplary embodiment of an apparatus according to present disclosure; 
           [0023]      FIG. 12  depicts an exemplary embodiment of a heating assembly for the apparatus depicted in  FIG. 11 ; 
           [0024]      FIG. 13  depicts an exemplary embodiment of a process to prepare food substances. 
       
    
    
       [0025]    In the following description, like reference numbers are used to identify like elements. Furthermore, the drawings are intended to illustrate major features of exemplary embodiments in a diagrammatic manner. The drawings are not intended to depict every feature of every implementation nor relative dimensions of the depicted elements, and are not drawn to scale. 
       DETAILED DESCRIPTION 
       [0026]    In the following description, numerous specific details are set forth to clearly describe various specific embodiments disclosed herein. One skilled in the art, however, will understand that the presently claimed invention may be practiced without all of the specific details discussed below. In other instances, well known features have not been described so as not to obscure the invention. 
         [0027]    In one exemplary embodiment, apparatus  10 , shown in  FIGS. 1   a - b , may be used to prepare food substances and/or food products including, but not limited to, pizza, flat breads, traditional breads, and the like according to the present disclosure. Apparatus  10  may have heating assemblies  20  and a heating assembly  30 . Although two heating assemblies  20  are depicted in  FIG. 1 , it is to be understood that apparatus  10  may operate with only one heating assembly  20 . 
         [0028]    As shown in  FIGS. 1   a - b  and  2 , the exemplary apparatus  10  may be configured to allow the heating assemblies  20  to move with respect to the stationary heating assembly  30  using wheels  40  on the frame  50 . In another exemplary embodiment (not shown), apparatus  10  may be configured to allow the heating assembly  30  to move with respect to stationary heating assemblies  20 . 
         [0029]    The heating assemblies  20  may contain a support surface  60  for supporting food during the preparation process and a heating mechanism  70  dedicated to heating the support surface  60  regardless of where the heating assembly  20  is with respect to the heating assembly  30 . The heating mechanism  70  may be any means of heating known to those of ordinary skill in the art including fire, hot coals, infrared, electric, gas, convection and hot air impingement, among others and is possibly thermostatically controlled. 
         [0030]    In one exemplary embodiment, the heating mechanism  70 , as shown in  FIGS. 1   a - b ,  2 ,  3  and  4 , heats the support surface  60  by supplying gas mixed with air through hose  80  to pipes  90 . As the gas and air mixture escapes through the openings  100  of the pipes  90 , the gas and air mixture may be ignited using, for example, a gas pilot light as known in the art. Once the gas and air mixture is ignited, the resulting fire constantly heats the support surface  60  allowing for the most intense and rapid heat transfer to take place as the food product is placed on the support surface  60 . This rapid heat transfer that takes place between the constantly heated support surface  60  and the food product further results in a reduced bake time and a baking process that effectively causes food substances to start baking from the bottom-up before applying heat from the heating assembly  30 . 
         [0031]    The heating assembly  30  may contain a heating mechanism  140  configured to heating food product on the support surface  60  as the heating assembly  20  is positioned under the heating assembly  30 . The heating mechanism  140  may be any means of heating known to those of ordinary skill in the art including fire, hot coals, infrared, electric, gas, convection and hot air impingement, among others and is possibly thermostatically controlled. 
         [0032]    In one exemplary embodiment, the heating assembly  30 , as shown in  FIGS. 1   a - b ,  5  and  8   a - d , may contain a cover  110 , exhaust pipes  120 , heating tubes  130 , gas supply system  150 , and gas ignition system  160 . As the gas travels through the gas supply system  150 , it is mixed with air and expelled through openings  180  of nozzles  170  shown in more detail in  FIGS. 7   a - d . The gas ignition system  160 , using, for example, a gas pilot light system as known in the art, ignites the mixture of gas and air expelled through the nozzles  170  causing a fire that heats the air inside the heating tubes  130 . As the heating tubes  130  get hot, the exhaust escapes through the exhaust pipes  120  and away from the operator of the apparatus  10 . 
         [0033]    In one exemplary embodiment, the gas supply system  150  may contain an air blower  190  configured to supply air through air valve  200  for mixing with the gas supplied through a safety magnet gas controller  250  and a gas valve  210 . 
         [0034]    In another exemplary embodiment, the gas ignition system  160  may contain a safety magnet gas controller  260  and a gas valve  270  for supplying gas to a gas pilot light system as known in the art for igniting air and gas mixture expelled through openings  180  of nozzles  170 . Should the air blower  190  stop working, a micro switch  290  may be used to shut off the apparatus  10  and the supply of gas using solenoid gas shut off valves  230 ,  240  and the safety magnet gas controllers  250 ,  260 . 
         [0035]    The apparatus  10  may have an on/off switch  220  for turning on the air blower  190  and igniting the air and gas mixtures in the heating assemblies  20  and  30 . The apparatus  10  may further have a gas pressure regulator  300  for controlling and/or detecting any spikes in the amount of gas being delivered to the apparatus  10 . The apparatus  10  may also have a temperature limit controller  280  for controlling and/or detecting when the temperature is not optimal for cooking. 
         [0036]    In another exemplary embodiment, apparatus  195  shown in  FIG. 9 , may be used to prepare food substances and/or food products including, but not limited to, pizza, flat breads, traditional breads, and the like according to the present disclosure. Apparatus  195  may have a heating assembly  201  and a heating assembly  205 . Although not shown, one skilled in the art would understand that the apparatus  195  may have a frame for supporting the heating assemblies  201  and  205 . 
         [0037]    Referring to  FIGS. 9 and 10 , the heating assembly  201  may contain rotatable support surface  211  for supporting food during the preparation process and heating mechanism  71  dedicated to heating the rotatable support surface  211  as it is rotated about axis  231  in the directions as represented by arrow  241 . As described above, the heating mechanism  71  may be any means of heating known to those of ordinary skill in the art including fire, hot coals, infrared, electric, gas, convection and hot air impingement, among others and is possibly thermostatically controlled. In one exemplary embodiment, the heating mechanism  71  is the same as the heating mechanism  70 , described in more detail above. In one exemplary embodiment, the rotatable support surface  211  is substantially circular in shape. In another exemplary embodiment, the rotatable support surface  211  is substantially rectangular in shape. 
         [0038]    The rotatable support surface  211  may be configured to rotate about the axis  231  using, for example, a post  261  that is rotatably connected with the heating assembly  205 . In another exemplary embodiment (not shown), the apparatus  195  may have a frame (not shown) and wheels (not shown) that would support the rotatable support surface  211  and would allow the rotatable support surface  211  to rotate about the axis  231 . Although not shown, one skilled in the art would understand that the apparatus  195  may have handles and/or other safety features that would allow a baker to rotate the rotatable support surface  211  without burning their hands. 
         [0039]    Referring to  FIG. 9 , the heating assembly  205  may contain a cover  250  and a heating mechanism  271  configured to heating food product on the rotatable support surface  211  as the rotatable support surface  211  is rotated about axis  231  to position the food product under the heating assembly  205 . The heating mechanism  271  may be any means of heating known to those of ordinary skill in the art including fire, hot coals, infrared, electric, gas, convection and hot air impingement, among others and is possibly thermostatically controlled. In one exemplary embodiment, the heating mechanism  271  is the same as the heating mechanism  70 , described in more detail above. In another exemplary embodiment, the heating mechanism  271  is the same as the heating mechanism  140 , described in more detail above. 
         [0040]    In another exemplary embodiment, the heating element  71  may be configured to rotate with the rotatable support surface  211  as the food product is being positioned under the heating element  271 . 
         [0041]    Having the rotatable support surface  211  be constantly heated by the heating element  71  allows for the most intense and rapid heat transfer to take place as the food product is placed on the rotatable support surface  211 . This rapid heat transfer that takes place between the constantly heated rotatable support surface  211  and the food product further results in a reduced bake time and a baking process that effectively causes food substances to start baking from the bottom-up before applying heat from the heating assembly  205 . 
         [0042]    In another exemplary embodiment, apparatus  291  shown in  FIGS. 11   a - b , may be used to prepare food substances and/or food products including, but not limited to, pizza, flat breads, traditional breads, and the like according to the present disclosure. Apparatus  291  may have a heating assembly  301  and a heating assembly  310 . Although not shown, one skilled in the art would understand that the apparatus  291  may have a frame for supporting the heating assemblies  301  and  310 . 
         [0043]    Referring to  FIGS. 11   a - b  and  12 , the heating assembly  310  may contain rotatable support surface  320  for supporting food during the preparation process and a rotatable heating mechanism  370  dedicated to constantly heat the rotatable support surface  320  as they are both rotated about axis  330  in the directions as represented by arrow  340 . As described above, the rotatable heating mechanism  370  may be any means of heating known to those of ordinary skill in the art including fire, hot coals, infrared, electric, gas, convection and hot air impingement, among others and is possibly thermostatically controlled. In one exemplary embodiment, the rotatable heating mechanism  370  is the same as the heating mechanism  70 , described in more detail above. In one exemplary embodiment, the rotatable support surface  320  is substantially semicircular in shape. In another exemplary embodiment, the rotatable support surface  320  is substantially rectangular in shape. 
         [0044]    Referring to  FIGS. 11   a - b , the rotatable support surface  320  and the rotatable heating mechanism  370  may be configured to rotate about the axis  330  using, for example, a post  360  that is rotatably connected with the heating assembly  301 . In another exemplary embodiment (not shown), the apparatus  291  may have a frame (not shown) and wheels (not shown) that would support the rotatable support surface  320  and/or the rotatable heating mechanism  370  and would allow the rotatable support surface  320  and the rotatable heating mechanism  370  to rotate about the axis  330 . Although not shown, one skilled in the art would understand that the apparatus  291  may have handles and/or other safety features that would allow a baker to rotate the rotatable support surface  320  and the rotatable heating mechanism  370  without burning their hands. 
         [0045]    Referring to  FIG. 11 , the heating assembly  301  may contain a cover  380  and a heating mechanism  390  configured to heat food product on the rotatable support surface  320  as the rotatable support surface  320  is rotated about axis  330  to position the food product under the heating assembly  300 . The heating mechanism  390  may be any means of heating known to those of ordinary skill in the art including fire, hot coals, infrared, electric, gas, convection and hot air impingement, among others and is possibly thermostatically controlled. In one exemplary embodiment, the heating mechanism  390  is the same as the heating mechanism  70 , described in more detail above. In another exemplary embodiment, the heating mechanism  390  is the same as the heating mechanism  140 , described in more detail above. 
         [0046]    Having the rotatable support surface  320  be constantly heated by the rotatable heating mechanism  370  allows for the most intense and rapid heat transfer to take place as the food product is placed on the rotatable support surface  320 . This rapid heat transfer that takes place between the constantly heated rotatable support surface  320  and the food product further results in a reduced bake time and a baking process that effectively causes food substances to start baking from the bottom-up before applying heat from the healing assembly  301 . 
         [0047]    Referring to  FIG. 13 , the following exemplary process may be used to prepare food substances using any of the apparatuses according to the present disclosure. Referring to step S 10 , process starts by preparing dough by mixing flour with small amount of water and/or other liquids. Referring to step S 20 , process may continue by proofing the dough by allowing it to rise. Referring to step S 30 , process may continue by shaping the dough to have a specific thickness and shape using a dough sheeter and/or hands. Referring to step S 40 , process may continue by at least partially spraying the dough with water. Referring to step S 50 , the process continues by hitting the wetted dough against the constantly heated surface, for example, support surfaces  60 ,  211 ,  320  described above. Hitting the wetted dough against the constantly heated surface allows for the most intense and rapid heat transfer to take place. This rapid heat transfer that takes place between the constantly heated surface and the food product further results in a reduced bake time and a baking process that effectively causes food substances to start baking from the bottom-up. Referring to step S 60 , the process continues by applying heat to the top of the dough there by causing the dough to bake from top to bottom. Step S 60  may, for example, take about 10-20 seconds. Referring to step S 70 , the process continues by removing the cooked food product from the heat. Referring to step S 80 , the process may continue by spraying the food product with water to make it less brittle. 
         [0048]    While several illustrative embodiments of the invention have been shown and described, numerous variations and alternative embodiments will occur to those skilled in the art. Such variations and alternative embodiments are contemplated, and can be made without departing from the scope of the invention as defined in the appended claims. 
         [0049]    As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. The term “plurality” includes two or more referents unless the content clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosure pertains. 
         [0050]    The foregoing detailed description of exemplary and preferred embodiments is presented for purposes of illustration and disclosure in accordance with the requirements of the law. It is not intended to be exhaustive nor to limit the invention to the precise form(s) described, but only to enable others skilled in the art to understand how the invention may be suited for a particular use or implementation. The possibility of modifications and variations will be apparent to practitioners skilled in the art. No limitation is intended by the description of exemplary embodiments which may have included tolerances, feature dimensions, specific operating conditions, engineering specifications, or the like, and which may vary between implementations or with changes to the state of the art, and no limitation should be implied therefrom. Applicant has made this disclosure with respect to the current state of the art, but also contemplates advancements and that adaptations in the future may take into consideration of those advancements, namely in accordance with the then current state of the art. It is intended that the scope of the invention be defined by the Claims as written and equivalents as applicable. Reference to a claim element in the singular is not intended to mean “one and only one” unless explicitly so stated. Moreover, no element, component, nor method or process step in this disclosure is intended to be dedicated to the public regardless of whether the element, component, or step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. Sec. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for . . . ” and no method or process step herein is to be construed under those provisions unless the step, or steps, are expressly recited using the phrase “step(s) for . . . .”