Patent Description:
In making dough products, it is known to form dough into a sheet between a pair of counter rotating sheeter rollers, stripping the dough from the back roller (e.g. with a wire) so that it adheres only to the front roller, and then cutting a pattern from the sheet by rotating a so-called cutter roller against the surface of the front roller.

The patterned sheet is then stripped from the front roller (e.g. with a wire), with the product pieces falling down onto a conveyor belt, and with the surrounding web of "rework" dough, if any, returning to the hopper above the two sheeter rollers to be recombined fresh dough or directing the rework to waste.

<CIT> discloses a specially shaped pizza plate in which a sheet of dough is cut out by a punch action to produce the base of the pizza. <CIT> discloses a dough processing machine for the production of pasta in which continuous dough blanks can be continuously punched out of a dough path by the rotation of a drum. The cutting device of this machine comprises a cutting surface containing a plurality of cutting elements, each cutting element comprising: a cutting edge at the top; an interior sidewall extending from a base to the top with an interior sidewall angle; an exterior sidewall extending from the base to the top with an exterior sidewall angle;wherein a portion of the exterior sidewall of one of the plurality of cutting elements touches a portion of the exterior sidewall of an adjacent one of the plurality of cutting elements. <CIT> discloses a shaper and cutter for biscuit dough comprising a polyamide block with a recess of the desired biscuit shape.

There is an ongoing need to reduce waste. Therefore, it would be desirable to provide a cutting roller that can efficiently cut the desired pattern while minimizing the amount of waste.

In one embodiment, the interior sidewall angle is greater than the exterior sidewall angle by about <NUM>° or more. In some instances, the interior sidewall angle is at least <NUM>° or more. Alternatively or additionally, the exterior sidewall angle is about <NUM>° or less.

In some embodiments, the interior sidewall angle ranges from about <NUM>° to about <NUM>°.

In some embodiments, the exterior sidewall angle is about <NUM>° to about <NUM>°.

A shoulder is provided on the interior sidewall between the base of the cutting element and the top of the cutting element. The shoulder has a base and a sidewall that extends from the shoulder base to the top of the cutting element at a shoulder sidewall angle. In one embodiment, the interior sidewall angle is greater than the shoulder sidewall angle by about <NUM>° degrees or more. In some instances, the interior sidewall angle is at least <NUM>° or more. Alternatively or additionally, the shoulder sidewall angle is about <NUM>° or less.

Typically, the shoulder base has a width that is greater than a width of the top flat surface and in some instances, the width of the shoulder is about <NUM> times or greater than the width of the top flat surface. In some embodiments, the shoulder has a height measured from a shoulder base to the top flat surface that is less than a height of the top flat surface measured from the top flat surface to the cutting surface. In these instances, the shoulder height may be between about <NUM>% to about <NUM>% of the height of the top surface.

In one aspect the exterior sidewall and shoulder sidewall define a cutting angle such that the cutting angle is less than the interior side wall angle and, in some instances is about <NUM>° less.

The cutting element may have any suitable shape such as a parallelogram, circle, oval, ellipse, or a complex geometrical shape. In one embodiment the at least one cutting element is an ellipse and, it is contemplated that all the cutting elements are elliptical. In those instances, where the cutting element is elliptical, each ellipse has a major axis that is between about <NUM> to about <NUM> times longer than a minor axis.

It is also contemplated that the size of the cutting elements may be the same or different and in one embodiment, all the cutting elements have a size that is equal.

The apparatus includes a plurality of cutting elements, the cutting elements are arranged such that a portion of the exterior sidewall of one of the plurality of cutting elements touches a portion of the exterior sidewall of an adjacent one of the plurality of cutting elements. In other embodiments, the cutting elements may be arranged such that a portion of the exterior sidewall of one of the plurality of cutting elements touches a portion of the exterior sidewall of at least four adjacent one of the plurality of cutting elements. In yet other embodiments, the cutting elements may be arranged such that a portion of the exterior sidewall of one of the plurality of cutting elements touches a portion of the exterior sidewall of six adjacent one of the plurality of cutting elements.

By controlling the geometry of the cutting elements and the pattern of the cutting elements on the cutting surface, it has been found that the amount of waste can be reduced while efficiently cutting the dough to provide a plurality of similarly shaped foodstuffs. For example, where the cutting elements are elliptical, the cutting elements may be arranged in alternating rows such that the ends of the major axis of each cutting element in one row are approximately at the center point of the cutting elements in the adjacent row. As a result, a gap is created that has a generally triangular shape with curvilinear sides. In some aspects the volume of the gap is at least <NUM> times less than the volume of each cutting element.

The inventions extend to methods, systems, kits of parts and apparatus substantially as described herein and/or as illustrated with reference to the accompanying figures.

The above aspects and other features, aspects, and advantages of the described apparatus may be better understood with regard to the following description, appended claims, and accompanying drawings.

It is to be understood by one of ordinary skill in the art that the present discussion is a description of specific embodiments only and is not intended to limit the broader aspects of the described apparatus.

Turning to <FIG>, a product assembly line <NUM> incorporating a cutting apparatus <NUM> is depicted. The product assembly <NUM> line has a sheet of dough <NUM> with a first surface <NUM> and a second surface <NUM> traveling from right to left upon a conveyor <NUM> that is moving in the direction shown by arrow <NUM>. Although not shown, it should be understood that the dough is formed in a batch maker or the like and transferred to the product assembly line <NUM> where it is processed into a dough sheet <NUM>. As shown in this portion of the product assembly line <NUM>, the sheet of dough <NUM> is delivered by conveyor <NUM> to the cutting apparatus <NUM>. As the dough sheet moves in a feed direction (indicated by the arrow <NUM>), the cutting apparatus <NUM> rotates in the direction indicated by the arrow <NUM>.

The cutting apparatus <NUM> includes a plurality, of cutting patterns, molds, or elements <NUM> disposed on an exterior or cutting surface <NUM> of a cylindrical, rotatably driven drum <NUM> for forming and cutting the dough sheet <NUM> into a desired number of uniform shaped pieces <NUM>. The plurality of cutting elements <NUM> are mounted relative to the conveyor <NUM> such that, when the dough sheet <NUM> is traveling in the feed direction <NUM>, the cutting elements <NUM> engage the dough sheet <NUM> to cut and sever the dough to provide a plurality of cuts in the dough sheet, resulting in the formation of individual dough pieces or products <NUM> and intermediate, recyclable dough pieces <NUM>. The drum <NUM> can be positively driven or driven by the frictional engagement between the cutting elements <NUM> and the dough sheet <NUM> or the conveyor <NUM>. In operation, the cutting elements <NUM> extend all the way through the dough sheet <NUM> to lightly engage the conveyor <NUM> and completely sever the dough sheet <NUM>.

It will be understood that the dough sheet <NUM> can have any suitable thickness, with, of course, a corresponding change in the size (height or depth) of the cutting elements <NUM>, in order to form products <NUM> of varying depth or thickness. After the cuts are made in the dough sheet <NUM>, the cut pieces <NUM> continue traveling on the conveyor <NUM> to a post processing station (not shown). The post processing station can include, for example, proofing, baking, freezing and/or packaging.

In other embodiments, it is contemplated that the cutting elements <NUM> are provided on a surface of a pressing element instead of a rotating drum such that the pressing element intermittently contacts a portion of a dough sheet to cut the dough sheet into a desired number of uniform shaped pieces.

In one aspect, the rotating drum <NUM> may be mounted on a drive shaft <NUM>. Side plates <NUM> (only one of which is shown) may be mounted on either side of the rotating drum <NUM>. The side plates <NUM> may each include an elongated side end portion <NUM>, respectively, that extend in the direction of travel <NUM> of the dough sheet. Each elongated side end portions <NUM> includes a notch <NUM> to receive a pivot shaft <NUM> that extends parallel to the drive shaft <NUM>. The pivot shaft <NUM> allows the rotating drum <NUM> and the drive shaft <NUM> to pivot and lift up off of the dough sheet <NUM> when desired, such as at the end of a production cycle. A dough roller (not shown) may be freely rotatably mounted on the pivot shaft <NUM>.

It will be appreciated that a plurality of the cutting elements <NUM> are disposed on the exterior of the rotating drum <NUM> to define a cutting surface <NUM>. The cutting elements <NUM> may be disposed or provided on the exterior surface in any suitable manner. In one embodiment, the various cutting elements <NUM> are provided as part of a sleeve that extends about exterior surface and is secured for rotation with the drum <NUM>. Alternatively, the cutting elements <NUM> may be provided directly on exterior surface by any suitable means depending on the material forming the cutting elements. For example, the cutting elements <NUM> may be provided by engraving, laser etching, or the like. It is contemplated that various suitable materials could be used for the cutting elements <NUM> such as metals, plastics, coated metals, and the like. As an example, the cutting elements could be formed from a metal such as stainless steel coated with polytetrafluoroethylene.

Referring to <FIG>, a plan view of a portion of the cutting pattern or cutting surface <NUM> provided on the rotating drum <NUM> to form the cutting apparatus <NUM> is shown. It will be appreciated that the cutting pattern or cutting surface <NUM> has dimensions suitable to completely cover or encircle the drum <NUM>. It will be appreciated that the cutting surface <NUM> contains a plurality of cutting elements <NUM> each of which have the same or substantially the same shape.

Each cutting element <NUM> may have any suitable shape such as a parallelogram, circle, oval, ellipse, or a complex geometrical shape generally defined by its exterior sidewall <NUM> (shown in <FIG>). In one embodiment as best seen in <FIG>, the cutting elements <NUM> are elliptical and, it is contemplated that all the cutting elements <NUM> are elliptical. In those instances where the cutting element <NUM> is elliptical, each ellipse has a major axis <NUM> and a minor axis <NUM> such that their intersection defines the center or center point <NUM>.

The length of the major axis <NUM> is from about <NUM> to about <NUM> or about <NUM> to about <NUM>, or about <NUM> to about <NUM> and may be about <NUM> to about <NUM> of about <NUM>. The length of the minor axis is from about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>. In some aspects, the major axis is about <NUM> to about <NUM> times longer than the length of the minor axis <NUM>. The lengths of the major axis <NUM> and the minor axis <NUM> are measured as the distance from each of the respective exterior side walls <NUM>.

Referring back to <FIG>, where the cutting elements <NUM> are shown as elliptical, the cutting elements <NUM> may be arranged in alternating rows such that the ends of the major axis <NUM> of each cutting element <NUM> in one row are approximately at the center point <NUM> of the cutting elements <NUM> in the adjacent row. It will also be appreciated that the plurality of cutting elements <NUM> are arranged such that a portion of the exterior sidewall <NUM> of one of the plurality of cutting elements <NUM> touches a portion of the exterior sidewall <NUM> of an adjacent one of the plurality of cutting elements <NUM>. In other embodiments, the cutting elements <NUM> may be arranged such that a portion of the exterior sidewall <NUM> of one of the plurality of cutting elements <NUM> touches a portion of the exterior sidewall <NUM> of at least four adjacent one of the plurality of cutting elements <NUM>. In yet other embodiments, the cutting elements <NUM> may be arranged such that a portion of the exterior sidewall <NUM> of one of the plurality of cutting elements <NUM> touches a portion of the exterior sidewall <NUM> of six adjacent one of the plurality of cutting elements <NUM>.

It will also be appreciated that by arranging the cutting elements <NUM> in a manner so that a portion of the exterior sidewall <NUM> of one of the plurality of cutting elements <NUM> touches a portion of the exterior sidewall <NUM> of adjacent one of the plurality of cutting elements <NUM>, interstitial gaps <NUM> are created. In some instances, the interstitial gaps <NUM> are generally triangular shaped with curvilinear (concave) sides. In some aspects the volume of the interstitial gap <NUM> is at least <NUM> times less than the volume of each cutting element <NUM>.

In those instances where the cutting elements <NUM> are elliptical and the cutting elements are arranged so that a portion of the exterior sidewall <NUM> of one of the plurality of cutting elements <NUM> touches a portion of the exterior sidewall <NUM> of at least two adjacent cutting elements, two of the sides 94a, 94b may have generally the same length and one of the sides <NUM> may be longer than the other two sides. The two sides 94a, 94b, which are shorter, may have a length from about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>. The long side <NUM> may have a length from about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>. By arranging the cutting elements <NUM> in an appropriate manner, the size or volume of the interstitial gaps <NUM> are small, which reduces the amount of waste (or recyclable) pieces <NUM>.

It is also contemplated that, in some embodiments, each cutting element <NUM> may be spaced from adjacent cutting elements <NUM>. In other words, in this instance, each cutting element <NUM> does not touch another cutting element <NUM> and there is a gap between each adjacent cutting element <NUM>.

Turning now to <FIG> and <FIG>, a cross-sectional view of a single cutting element <NUM> is depicted. Each cutting element <NUM> has a top <NUM> that has a flat surface <NUM> with a width <NUM>. The width <NUM> of the top refers <NUM> to the width at the top of the cutting element <NUM> (and may be considered the thickness of the cutting element). The width <NUM> of the top ranges from about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>.

The top surface <NUM> is at a cutting element height or cutting depth <NUM>, which is the distance between the top surface <NUM> and the top of the cutting surface <NUM>. The cutting element height of cutting depth <NUM> may differ depending on the thickness of the dough. In one instance, when the dough has a thickness of approximately <NUM> to about <NUM>, the element height (or cutting depth) <NUM> may be in the range of about <NUM> to about <NUM>, or about <NUM>.

Each cutting element <NUM> has an interior sidewall <NUM> and an exterior sidewall <NUM>. The interior sidewall <NUM> extends from the top of the cutting surface <NUM> toward the top surface <NUM> at an interior sidewall angle <NUM>. The exterior sidewall <NUM> extends from the top of the cutting surface <NUM> to the top surface <NUM> at an exterior sidewall angle <NUM>. As best seen in <FIG>, the interior <NUM> and exterior <NUM> sidewall angles refer to the angle of the sidewalls with respect to an imaginary line <NUM> that is normal to the top of the cutting surface <NUM>. The interior sidewall angle <NUM> is also referred to as a release angle which is relevant to the cutting of dough. It is desirable that the interior sidewall angle <NUM> be larger than both the exterior sidewall angle <NUM> and the cutting angle, which will be defined in more detail below so that the cutting elements <NUM> release from the dough after cutting the dough.

It will be appreciated that the interior sidewall angle <NUM> is greater than the exterior sidewall angle <NUM>. In various embodiments, the interior sidewall angle <NUM> can be greater than the exterior sidewall angle <NUM> by about <NUM>° or more, or by about <NUM>° or more, or by about <NUM>° or more, or by about <NUM>° or more. In some instances, the exterior sidewall angle <NUM> ranges from about <NUM>° to about <NUM>° or from about <NUM>° to about <NUM>°, or about <NUM>° to about <NUM>°, or about <NUM>°. In some instances, the interior sidewall angle <NUM> ranges from about <NUM>° to about <NUM>°, or from about <NUM>° to about <NUM>°, or about <NUM>°.

Turning back to <FIG>, the interior sidewall <NUM> is provided with a shoulder <NUM> that is disposed between the top surface <NUM> and the top surface of the cutting surface <NUM>. The shoulder <NUM> interrupts the interior sidewall <NUM> so that the interior sidewall <NUM> does not extend to the top wall <NUM>. Instead, the shoulder <NUM> is provided with a sidewall <NUM> that extends from a base of the shoulder <NUM> to the top <NUM> at a shoulder sidewall angle <NUM>. Referring to <FIG>, the shoulder sidewall angle <NUM> is the angle between the shoulder sidewall angle <NUM> and an imaginary line <NUM> that is normal to the top of the cutting surface <NUM>.

In some aspects the shoulder sidewall angle <NUM> may be the same or substantially the same as the interior sidewall angle <NUM>. In other aspects the shoulder sidewall angle <NUM> differs from the interior sidewall angle <NUM>. In various embodiments, the interior sidewall angle <NUM> can be greater than the shoulder sidewall angle <NUM> by about <NUM>° or more, or by about <NUM>° or more, or by about <NUM>° or more, or by about <NUM>° or more. In one aspect, the shoulder sidewall angle <NUM> ranges from about <NUM>° to about <NUM>°, or about <NUM>° to about <NUM>° and in some instances is about <NUM>°.

The base of the shoulder <NUM> has a width <NUM> that is larger than the width of the top <NUM>. In some instances the width of the shoulder <NUM> is about <NUM> to about <NUM> times larger than the width of the top <NUM>, or about <NUM> to about <NUM> times or about <NUM> times larger than the width of the top <NUM>. The shoulder width <NUM> ranges from about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>.

In addition, the shoulder has a height <NUM> that is the height as measured from the shoulder base <NUM> to the top flat surface <NUM>. The shoulder height <NUM> is less than the cutting element height <NUM>. In some instances, the shoulder height <NUM> is about <NUM>% to about <NUM>% of the cutting element height <NUM>. In some aspects, the shoulder height <NUM> is about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM> to about <NUM>, or about <NUM>.

As best seen in <FIG>, the combination of the exterior sidewall angle <NUM> and the shoulder sidewall angle <NUM> define a cutting angle <NUM>. In some instances, the cutting angle <NUM> ranges from about <NUM>° to about <NUM>°, or about <NUM>° to about <NUM>°, or about <NUM>° to about <NUM>°, or about <NUM>°. Desirably the cutting angle <NUM> is small to effectively cut the dough and in some instances, the cutting angle <NUM> is smaller than the release angle.

Advantageously, by providing the above described cutting elements, substantially similar dough pieces <NUM> can be produced without creating an undesirable amount of waste.

Claim 1:
An apparatus comprising:
a cutting surface (<NUM>) containing a plurality of cutting elements (<NUM>), each cutting element comprising:
a top (<NUM>) with a flat surface (<NUM>);
an interior sidewall (<NUM>) extending from a base (<NUM>) to the top (<NUM>) with an interior sidewall angle (<NUM>);
an exterior sidewall (<NUM>) extending from the base (<NUM>) to the top (<NUM>) with an exterior sidewall angle (<NUM>) wherein a portion of the exterior sidewall (<NUM>) of one of the plurality of cutting elements (<NUM>) touches a portion of the exterior sidewall (<NUM>) of an adjacent one of the plurality of cutting elements (<NUM>);
wherein the interior sidewall angle (<NUM>) is different than the exterior sidewall angle (<NUM>); and
a shoulder (<NUM>) provided on the interior sidewall (<NUM>) between the base (<NUM>) of the cutting element and the top (<NUM>) of the cutting element;
wherein the shoulder (<NUM>) has a base (<NUM>) and a sidewall (<NUM>) that extends from the shoulder base to the top (<NUM>) of the cutting element at a shoulder sidewall angle.