Abstract:
An apparatus for caramelizing a cut surface of a split bread product is provided. The apparatus comprises a substantially flat heatable surface and at least one raised surface portion in heat transfer communication with the flat surface, and extending upwardly therefrom. The raised surface portion defines an upper contact surface for receiving and supporting the split bread product. The contact surface is formed to substantially conform to the contour of the cut surface of the split bread product, to apply heat directly to the cut surface to caramelize the inner surface.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not Applicable 
       STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT 
       [0002]    Not Applicable 
       BACKGROUND 
       [0003]    The present invention relates to an apparatus for grilling or searing the inner surfaces of baked bread products, such as buns, in order to enhance the flavor of the product and to mitigate the migration of liquids, e.g. juices, sauces, etc., into the body of the bread product. 
         [0004]    Sandwiches, burgers and the like are frequently served on toasted buns. Toasting enhances the texture and flavor provided by the bun. Buns are commonly toasted by means of a toaster, or by placement on a barbeque griddle. However, the toasting process may dry out the bun, which may be undesirable to the taste of some. 
         [0005]    Buns can be partially toasted or seared by briefly placing the split bread product on a flat heated surface, e.g. a griddle. Such partial toasting or searing may be effective to caramelize the inner surfaces of the bun, while allowing the body portions of the bun to remain bakery fresh in texture, flavor and appearance. In addition to providing flavor and texture to the taste of the bun, the caramelization may also be effective to mitigate the migration of juices and sauces from the burger, vegetables, etc., into the body of the bun, keeping the bun from quickly becoming soggy as the burger or sandwich awaits consumption. 
         [0006]    However, some bread products, such as buns and rolls, have been found to have a somewhat arcuate inner surface after splitting. As such, simply placing the bun or roll on a flat heated surface may well result in caramelizing only the outer edges of the bun or roll, leaving the inner surfaces substantially un-caramelized. In such a case, the cut surfaces of the bun do not have a caramelized flavor or texture, and meat and vegetable juices can more readily migrate into the body of the bun or roll, making it soggy. 
         [0007]    In some cases a press or weight is placed on the bun to urge the cut surface of the bun into contact with the heated surface, caramelizing the inner surface of the bread product. However, the process typically distorts the visual appearance of the bun, and distorts the texture of the bun so the body is not longer bakery fresh in taste. 
         [0008]    U.S. Pat. No. 6,736,051 to Franz et al discloses a Floating Clamshell Griddle Toaster which allows for toasting a bun or roll on a flat heated surface. The disclosed device includes a series of vertically translatable pins, which apply slight weight onto the bun to urge the inner surface into contact with the heated flat surface, without distorting or compressing the product to significant levels. The apparatus disclosed in the patent is effective to form a caramelized layer across the inner surface of the bun while maintaining the delicate shape and texture of the bun. However, the mechanical complexity of the device and the need for properly sizing and mating the pin plate to the griddle surface are factors limiting its practical use. 
         [0009]    Accordingly, it is an object of the present invention to provide an apparatus and method effective to caramelize the inner surfaces of split bread products in a manner that is readily usable on a variety of different cooking surfaces. 
         [0010]    It is a further object of the invention to provide an apparatus and method for caramelizing the inner surfaces of split bread products without distorting the appearance or texture of the body of the product. 
         [0011]    It a further object of the invention to provide such an apparatus and method which is readily adaptable to different sizes and shapes of bread products. 
       BRIEF SUMMARY 
       [0012]    An apparatus for caramelizing a cut surface of a split bread product is provided. The apparatus comprises a substantially flat heatable surface and at least one raised, bun toasting surface portion in heat transfer communication with the flat surface, and extending upwardly therefrom. The raised surface portion defines an upper contact surface for receiving and supporting the split bread product. The contact surface is formed to conform to the contour of the cut surface of the split bread product, to apply heat directly to the cut surface to caramelize the inner surface. 
         [0013]    In a preferred embodiment the contact surface defines an arcuate surface. In alternate embodiments the contact surface may be formed to be less arcuate, or substantially flat. 
         [0014]    The raised surface portion may be formed in different shapes to conform to the bread product being caramelized, e.g. a circular bun, a square bun, or an elongated roll. 
         [0015]    The upper contact surface may be sized and shaped to be slightly smaller than the perimeter of the bun, so that the bun edge portion extends beyond the raised surface portion. In alternate embodiments, the raised surface portion may be co-extensive with or slightly less than the cut surface of the split bread product. 
         [0016]    The raised surface portion may define an outer perimeter having a curved edge extending thereabout to facilitate receipt and engagement of the split bread product on the raised surface portion. 
         [0017]    Because the top and bottom surfaces of the split bread product may define different contours after splitting, the raised surface portions may be formed differently to caramelize top and bottom surfaces of a bun or other product. For example, the contact surface for receiving a bun top portion is preferably more arcuate than the contact surface formed to engage a bun bottom portion. In some cases the contact surface for receiving a bun bottom portion may be formed to be substantially flat. 
         [0018]    The raised surface portions may be formed integral with the heated surface, from a single piece of material. Alternatively, the raised surface portions may be formed as separate elements which are in heat transfer communication with the heated surface. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]    These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which like numbers refer to like parts throughout, and in which: 
           [0020]      FIG. 1  is a front perspective view of an apparatus constructed in accordance with the present invention; 
           [0021]      FIG. 2   a  is a top view of a heated surface including exemplary raised surface portions for caramelizing round buns or rolls; 
           [0022]      FIG. 2   b  is a top view of a heated surface including alternate raised surface portions for caramelizing square buns or rolls; 
           [0023]      FIG. 2   c  is a top view of a heated surface including alternate raised surface portions for caramelizing elliptically shaped buns or rolls; 
           [0024]      FIG. 3  is a sectional view of the heated surface showing exemplary raised surface portions; 
           [0025]      FIG. 4  is an enlarged sectional view of a portion of  FIG. 3 ; 
           [0026]      FIG. 5  is an enlarged sectional view of a another portion of  FIG. 3 ; 
           [0027]      FIG. 6  is an illustration of inner surface portions of buns that have been caramelized in accordance with the present invention; and 
           [0028]      FIG. 7  is an illustration of the heated surface having different shaped protrusions and a flat surface area for warming the buns after caramelization. 
       
    
    
     DETAILED DESCRIPTION 
       [0029]    The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise various other embodiments that are within the scope and spirit of the invention disclosed herein. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments. 
         [0030]      FIG. 1  illustrates an apparatus for toasting split bread products such as rolls, buns and other bread products. For ease of reference, such various bread products are collectively referred to as buns herein, except where distinctions of size or shape are noted. Toasting apparatus  10  includes a housing  11  and a griddle  13 , which includes heated upper surface  16 . The griddle  13  may be heated by various means, such as by electrical heating conduits disposed in the body of the griddle  13 , or disposed in a separate heating element that is in thermal communication with griddle  13 . The temperature of the griddle upper surface  16  may be regulated by means of heat control system  19 , disposed within housing  11 . As also shown in  FIG. 2 , the griddle upper surface  16  includes a plurality of pedestals or raised surface portions  15 ,  17 . As explained in more detail below, the raised surface portions  15 ,  17  may be formed in different shapes and sizes depending upon the particular bread product to be toasted, whether a top and/or bottom portion of the bun is to be toasted, and other factors effecting the contour of the split bread product. 
         [0031]    The raised surface portions  15 ,  17 , are shaped to provide abutting support to the bun, along the cut surfaces of the bun. 
         [0032]    As previously noted, efforts to toast or sear the inside surface of buns by simply placing the product on a flat heated surface have generally produced less than desirable results. Most commonly, the edge portions of the bun become toasted while the inside surface remains soft and non-caramelized. From experimentation, it appears that the cut surface of the bun may contract after the product is split, whereas the edge portions either do not contract, or contract to a lesser degree. Presumably edge portions of the bun resist contraction due to the crustier nature of the outer surface, which may be attributed to the Maillard reaction which occurs when the bread product is baked. This contraction appears more pronounced in the top portion of the bun, which is typically less dense. The bottom portion of the bun is typically more dense and the bottom cut surface appears to typically exhibit less contraction along the cut line. 
         [0033]    As a result of contraction of the body of the bun top portion, the top cut surface of the bun commonly becomes slightly arcuate along the cut line. While the extent of the arcuate profile is limited, it may be sufficient to make it difficult to caramelize the cut surface of the bun top portion without distorting the appearance and texture of the bun. The present invention is directed to an apparatus and method to reliably caramelize the inner surfaces of buns without the penalties associated with forcing the bun to lie flat on a griddle surface. 
         [0034]      FIG. 3  provides a cross-sectional view of the griddle  13 , including raised surface portions  15 ,  17 . As shown at  FIG. 3 , the raised surface portions  15 ,  17  are preferably formed integral with the griddle  13 , from a single piece of material. This is intended to provide more uniform thermal characteristics along the griddle  13 . However, it is to be understood that alternate embodiments of the invention may be implemented wherein raised surface portions  15 ,  17  may be implemented as separable structures, engaged to and in thermal communication with griddle  13 . 
         [0035]    Raised surface portions  15 ,  17  define upper contact surfaces  43 ,  47 , and body portions  45 ,  49 , respectively. In the presently preferred embodiment the raised surface portions  15 ,  17 , are formed to be approximately 3.7 inches wide (diameter) and extend approximately 0.38 inches above the griddle upper surface  16 . The arcuate contact surface  43  has a vertical rise of approximately 0.19 inches (radius approximately 9.71 inches). The upper contact surface  47  is shown as substantially flat. However, as described below, the contact surface  47  may also be formed to include an arcuate surface portion similar to that shown at  FIG. 4 , wherein the vertical rise of the arcuate portion is less, e.g. 0.1 inches (radius approximately 14.5 inches). 
         [0036]    As shown in  FIG. 4 , raised surface portion  15  preferably defines an arcuate contact surface  43 , having a curved upper edge portion  31 , and a reverse curved lower edge portion  33 , extending thereabout. The space between the curved upper edge portion  31  and the reverse curved lower edge portion  33  allows for edge portion  35  of bun top portion  20   a  to extend beyond contact surface  43 . As a result, contact surface  43  is in abutting engagement to cut surface  51  of bun top portion  20   a , notwithstanding contraction of the body  55  when the bun is sliced. 
         [0037]    While  FIG. 4  shows the preferred construction where the bun top portion extends beyond the contact surface  51 , it is to be understood that in other embodiments the contact surface  51  may be coextensive with or wider than the bun cut surface  43 . 
         [0038]      FIG. 5  illustrates contour of raised surface portion  17  as substantially flat, i.e. less arcuate than the arcuate contour shown in  FIG. 4 . As shown therein, raised surface portion  17  includes contact surface  47 , formed to receive and abut against cut surface  53  of bun lower portion  20   b . As indicated above, the body  57  of bun lower portion  20   b  is typically more compressed than the body  55  of bun upper portion  20   a . As noted above, the more compressed body has not been found to assume an arcuate shape along the cut line when the bun is split. As such, a slightly arcuate or flat surface has been found to be useful to caramelize the cut surface  57  of the bun lower portion  20   b . It should be noted, however, that raised surface portion  15 ,  17  may both be formed to define an arcuate contact surface, such as surface  43 , including curved upper and lower edge portions extending thereabout. Such arcuate contact surfaces have been found to be effective for caramelizing the cut surfaces of both top and bottom portions. 
         [0039]    Moreover, insofar as the split surface  53  of the bun lower portion  20   b  tends to be less arcuate or flat, the contact surface  47  may be substantially coextensive with the bun cut surface  53 , where the bun edge portions are not so raised as to space the cut surface  53  from the contact surface  47 . However, it is to be understood that the contact surface  47  may alternately be longer or shorter than the length of the bun cut surface  53 . Edges  37 ,  39  of the raised surface portion  17  are preferably curved as shown, and separated by vertical side wall  41 . 
         [0040]    In practice, the bun top and/or bottom portions may be seated on the raised surface portions  15 ,  17  using slight downward pressure, by hand, along with a twisting motion. Such a practice has been found to be useful to ensure that the bun cut surface abuts against the contact surface of the raised surface portions  15 ,  17 . In some cases a user may prefer that the outer perimeter of the bun extends over and engages the edges of the raised surface portion, to more securely maintain the bun in place. However, the process of manually seating the bun on the raised surface portions has been found to require little pressure, which may be localized around the perimeter of the bun. The pressure is released before toasting, and has not been found to distort the appearance or texture of the bun. 
         [0041]    The invention allows for the raised surface portions  15 ,  17  to be shaped and sized in accordance with the shape, size and characteristics of the product to be toasted. Insofar as in commercial usage the shape of the bread products used are typically consistent and limited, the permanent or semi-permanent nature of the shapes of the raised surface portions  15 ,  17  does not appear to be significantly limiting in commercial application. Further, it is anticipated that users, such as fast food restaurants, may specify particular shapes, heights and procedures for seating the buns which are tailored to their particular bread products, their food production techniques, and the preferred food product characteristics that they wish to achieve. 
         [0042]      FIG. 6  shows a bun, including bun top portion  20   a  and bun bottom portion  20   b , after toasting in accordance with the present invention. As shown therein cut surfaces  51  and  53  are toasted along substantially the entire surface thereof. 
         [0043]      FIG. 7  shows a plurality of split buns which have been toasted on raised surface portions  15 ,  17  (e.g. for about 1-1½ minutes), and moved to flat surface area  16  (holding area) of griddle  13 . When the split buns are moved to the griddle the buns are typically supported on the griddle by the outer edge portion, and the cut surfaces are spaced from the griddle. As such, the cut surfaces are typically not further caramelized or colored. Moreover, placing the buns on the flat surface area  16 , after caramelizing the cut surfaces of the buns, allows for warming of the bun body, e.g. to about 120-140° F., so that the bun will remain warm after sale. 
         [0044]      FIG. 2   b  shows an alternate implementation wherein the raised surface portion  21 ,  23  are formed to have a substantially square shape. Such construction may be useful for square buns, bread and other products. 
         [0045]      FIG. 2   c  illustrates another embodiment wherein the raised surface portions  25 ,  27  are formed in the shape of an elongated roll, as may be consistent with the shape of hot dog rolls, hoagie rolls, French bread, etc. Where the top and bottom portions of the elongated roll may contract differently upon splitting, one of the raised surface portions, e.g. portion  25 , may be formed to have a more arcuate shape than raised surface portion  27 , as previously described in connection with  FIGS. 4 and 5 . Additionally, where the buns or other bread product are not completely split before toasting, the raised surface portions  25 ,  27 , may be formed to be substantially contiguous so that the bun can be placed on the raised surface portions without being completely split and separated. 
         [0046]    Accordingly, as indicated above, the present invention is amenable to various modifications and enhancements that allow for toasting of the split surfaces of various bread products. The raised surface portions may be formed to conform to the size and contour of the split bread product in use. Further, the desired degree of caramelization may be varied by adjusting temperature of the griddle and by the manner in which the bread product is seated on the raised surface portions. These and other objects and advantages may be accomplished while preserving the fresh from the bakery flavor of the body of the toasted bread product, even where the meat or vegetables have significant moisture content.