Patent Description:
It is often desirable to shape or size items of food in order that they are more easily consumed, more palatable, can be processed more easily, or are just more aesthetically pleasing. In the most basic sense this can be achieved by simply manually slicing a food item, such as a vegetable item, to create the desired shape or size. Whilst this is suitable for simple shapes and low volume, for more complicated shapes or higher volume applications, manual cutting is not practical.

Devices exist which automate the process of shaping and sizing, for example, vegetables.

These devices come in a variety of forms. One such device comprises a grid like cutting implement, the vegetable being forced through the grid with the aid of an attached lever or ram, slicing the vegetable along the gridlines. Other implements mount the vegetable therein and utilise a spinning motion to shear a portion of the outer surface creating a spiral shaped portion of vegetable. There also exists commercial devices comprising a drum into which a plurality of vegetable items are placed, the drum having an opening to a blade and rotating such that portions of the vegetables become exposed to the aperture and the blade and are sliced. The shape of the vegetable in this case being determined by the configuration of the aperture and the blade. <CIT> discloses cookie cutters produced in sets, each set consisting of jagged shapes, similar in shape or similar, of gradually decreasing sizes. <CIT> describes a rotary knife fixture for cutting spiral shaped pieces.

What all of the current devices have in common is a limitation on the shape which can be created from the food item. Simply forcing a vegetable through a two dimensional die or grid, or removing generally parallel slices from a food item limits the variety of shape that can be produced.

It is the object of the present invention to provide for the shaping and sizing of foodstuff in a manner which provides flexibility in terms of the shapes that may be created.

The invention is set out in the independent claims <NUM> and <NUM>. Preferable features are set out in the dependent claims. According to the invention there is provided a food processing apparatus for the cutting of foodstuff comprising: a first cutting means having a cross-sectional shape defining a first maximal external diameter and a first minimal internal diameter about a first central axis; a second cutting means having a cross-sectional shape defining a second maximal external diameter and a second minimal internal diameter about a second central axis, the second maximal external diameter of the second cutting means being greater than or equal to the first minimal internal diameter of the first cutting means.

Ideally, in use, the second cutting means makes an initial cut in the foodstuff before a subsequent cut is made by the first cutting means.

Alternatively, in use, the first cutting means makes the initial cut in the foodstuff before the subsequent cut is made by the second cutting means.

Advantageously, two cuts can be made which produce a one piece, three dimensional basket/grid/mesh effect.

Further advantageously, as a result of the relationship between the second maximal external diameter of the second cutting means and the first minimal internal diameter of the first cutting means, the first and second cuts overlap such that apertures in a side wall of a portion of cut foodstuff may be formed.

Preferably, the first and or second cutting means have a non-uniform cross-sectional shape.

Ideally, the first cutting means is an outer cutting means.

Preferably, the second cutting means is an inner cutting means.

Ideally, the initial cut is made in the foodstuff by the first or second cutting means forming a preliminary shape in the foodstuff, the preliminary shape having a central axis defined by the central axis of the cutting means used to make the initial cut.

Preferably, the preliminary shape is subsequently cut by the one of the first or second cutting means not utilised to make the initial cut, the subsequent cut being in a direction such that the central axis of the preliminary shape aligns with the central axis of the cutting means making the subsequent cut during the cutting operation.

Ideally, the initial and subsequent cuts are at least partially overlapping cuts.

Preferably, cutting of the preliminary shape forms a final shape having a basket, grid, or mesh effect.

According to the invention, the first and/or second cutting means comprise a plurality of helical cutting formations formed around their respective central axis.

Preferably, the helical cutting formations are formed radially around the central axis of the first and second cutting means.

Preferably, the first and second cutting means are first and second cutting cylinders, the cross sectional shape of which is defined by the helical cutting formations.

Ideally, the first and second cutting means comprise a first and second cutting blades respectively, locatable at respective leading edges thereof.

Preferably, the first and second cutting means extend from the respective leading edges thereof to respective trailing edges thereof forming the respective first and second cutting cylinders.

Preferably, the helical cutting formations encourage rotation of the foodstuff and/or the cutting means as the foodstuff is cut by the cutting means.

Ideally, the first and second cutting means rotate in opposing directions as they travel through the foodstuff, or as the foodstuff travels through said cutting means.

Ideally, the direction of sweep of the helical cutting formations of the first cutting means is oblique in relation to, or opposes, the direction of sweep of the helical cutting formations of the second cutting means.

Preferably, the sweep of helical cutting formations of the first and/or second cutting means is orientated at an angle of between <NUM> degrees and <NUM> degrees relative to the axial direction of the respective cutting means.

Ideally, the second maximal external diameter of the second cutting means is greater than the first minimal internal diameter of the first cutting means.

Preferably, the difference between the diameter of the second maximal external diameter of the second cutting means and the diameter of the first minimal internal diameter of the first cutting means is between <NUM> and <NUM> inclusive.

Ideally, the helical cutting formations comprise wedge shaped, square, rectangular, or rounded cutting formations.

Preferably, the helical cutting formations comprise cutting formations of wedge shaped, rectangular, square, or rounded cross-sectional shape.

Preferably, one or more surfaces of the helical cutting formations are tapered and/or swept such that foodstuff is encouraged to move at least partially through the cutting means.

Ideally, the first and/or second cutting means are mountable such that they are freely rotatable about their central axis.

Alternatively, the first and/or second cutting means are rotationally driven by cutter driving means about their central axis.

Further alternatively, the first and/or second cutting means are rotationally fixed and the foodstuff rotates as it is cut thereby.

Preferably, the foodstuff is freely rotatable as it moves through the cutting means.

Alternatively, the foodstuff is rotationally driven by foodstuff driving means.

Further alternatively, the foodstuff is rotationally fixed and the first and second cutting means rotate as they cut the foodstuff.

Ideally, the first and second cutting means are forced at least partially through the foodstuff.

Alternatively, the foodstuff is forced at least partially through the first and second cutting means.

Further alternatively, the first and second cutting means and the foodstuff are forced towards one another such that the foodstuff is forced at least partially through the first and second cutting means.

Preferably, the first and second cutting means cut completely through the foodstuff.

Alternatively, the first and second cutting means cut partially through the foodstuff and may be rotated and/or otherwise moved in a direction opposite to a cutting direction such that they can be removed from the partially cut foodstuff.

Preferably, the cutting direction is the direction in which the first and/or second cutting means travels through the foodstuff as the leading edge penetrates the foodstuff and travels therethrough to form a cut therein.

Ideally, axial movement or rotation of the first and/or second cutting means encourages passage of the foodstuff at least partially therethrough, and/or axial movement or rotation of the foodstuff encourages passage of the foodstuff at least partially through the first and/or second cutting means.

Preferable, the first and/or second cutting means comprise a cutting means mounting assembly.

Ideally, the first cutting means is mountable via mounting features extending from an outer surface thereof.

Alternatively, the first cutting means is mounted via mounting brackets, a mounting plate, or mounting tube means extending from proximal the leading or trailing edges of the first cutting means. Ideally, the second cutting means is mountable via a central axle or shaft which is coaxial with the central axis of the second cutting means.

Alternatively, the second cutting means is mounted via mounting brackets or a mounting plate extending from proximal the leading or trailing edges of the second cutting means.

Further alternatively, the second cutting means is not fixed/mounted and is forced through the foodstuff in a freely rotating manner.

Ideally, where the second cutting means is not fixed/mounted it may pass completely through and exit the foodstuff, and be reset such that it is ready to cut another portion of foodstuff.

An embodiment of the invention is now described by way of example and with reference to the accompanying drawings in which:.

The present teaching will now be described with reference to an exemplary food processing apparatus for the cutting of foodstuff. It will be understood that the exemplary food processing apparatus is provided to assist in an understanding of the present teaching and are not to be construed as limiting in any fashion. Furthermore, elements or components that are described with reference to any one Figure may be interchanged with those of other Figures or other equivalent elements if within the scope of the claims.

Referring now to the accompanying drawings, there is illustrated a food processing apparatus for the cutting of foodstuff comprising a first cutter <NUM> having a cross-sectional shape defining a first maximal external diameter <NUM> and a first minimal internal diameter <NUM> about a first central axis <NUM>. A second cutter <NUM> having a cross-sectional shape defining a second maximal external diameter <NUM> and a second minimal internal diameter <NUM> about a second central axis <NUM> is also provided. The second maximal external diameter <NUM> of the second cutter <NUM> is greater than or equal to the first minimal internal diameter <NUM> of the first cutter <NUM>. In use, the foodstuff is cut by the second cutter <NUM> before being cut by the first cutter <NUM>, or alternatively the first cutter <NUM> may make the first cut with the second cutter <NUM> making a second subsequent cut. The sizing of the cutters <NUM>, <NUM> results in the first cutter <NUM> forming an outer cutter <NUM> and the second cutter <NUM> forming an inner cutter <NUM>, the inner and outer cutters <NUM>, <NUM> making respective inner and outer cuts in the foodstuff relative to each other. In a preferable embodiment, the second maximal external diameter <NUM> of the second cutter <NUM> is greater than the first minimal internal diameter <NUM> of the first cutter <NUM>. In a most preferred embodiment, the difference between the diameter of the second maximal external diameter of the second cutter <NUM> and the diameter of the first minimal internal diameter of the first cutter <NUM> means is between <NUM> and <NUM> inclusive. However, it should be understood that this range is provided for example only and the invention is easily scalable to facilitate cutting of larger or smaller items of foodstuff and as such the differences in the aforementioned diameters may be any reasonable value given the scale of the cuts formed. Advantageously, two cuts can be made which produce a one piece, three dimensional basket/grid/mesh effect <NUM>, the apertures <NUM> in the basket/grid/mesh <NUM> being formed by the overlapping nature of the cuts, this overlapping being caused by the maximal external diameter <NUM> of the second cutter <NUM> being greater than the first minimal internal diameter <NUM> of the first cutter <NUM>. In the most typical case, the foodstuff is potato, however the skilled person would appreciate that the food processing apparatus could be used to cut any type of foodstuff having suitable solidity including but not limited to vegetables and fruit. In one example of use of the apparatus, the foodstuff is cut by the first cutter <NUM> forming a preliminary shape in the foodstuff, the preliminary shape having a central axis defined by the central axis <NUM> of the first cutter <NUM>. The preliminary shape is then subsequently cut by the second cutter <NUM> in a direction such that the central axis of the preliminary shape aligns with the central axis <NUM> of the second cutter <NUM> during the cutting operation. Essentially, this means that both the first and second cutters <NUM>, <NUM> cut the foodstuff along a common axis. Cutting of the preliminary shape by the second cutter <NUM> forms a final shape <NUM> having a basket, grid, or mesh effect. This alignment of axis during cutting ensures that an exterior wall of a final shape formed after cutting by both cutters <NUM>, <NUM> is of the desired thickness and that the two cuts made form the final shape as desired. It can also be seen in <FIG> that, as the second maximal diameter <NUM> of the second cutter <NUM> is greater than the first minimal diameter <NUM> of the first cutter <NUM>, the formations <NUM> formed by the first cutter <NUM> are integral with the formations <NUM> formed by the second cutter <NUM> by virtue of a join <NUM>, yet apertures <NUM> may still be formed in the walls of the final shape <NUM>. Again, as described above, the apparatus may work equally as well in a manner wherein the second cutter <NUM> makes the preliminary cut and the first cutter <NUM> makes the final cut.

In the embodiment shown in the drawings, the first and second cutters <NUM>, <NUM> comprise a hollow central portion <NUM>, <NUM> defined by a plurality of helical cutting formations <NUM>, <NUM> formed around their respective central axis <NUM>, <NUM>. It should be understood that at least the second cutter <NUM> may not be hollow. Typically, when using a non-hollow/solid second cutter <NUM>, a core will first be cut from the foodstuff into which the solid second cutter <NUM> may travel. The helical cutting formations <NUM>, <NUM> are formed radially around the central axis of the first and second cutters <NUM>, <NUM> in a swept fashion. The first and second cutters <NUM>, <NUM> form cutting cylinders <NUM>, <NUM>, which extend lengthwise along the central axis <NUM>, <NUM> of the first and second cutters <NUM>, <NUM>. The cross sectional shape of the cutting cylinders <NUM>, <NUM> is defined by the helical cutting formations <NUM>, <NUM>. The cross-sectional shape of the cutting cylinders <NUM>, <NUM> varies along their axial length due to the helical nature of the helical cutting formations <NUM>, <NUM>, however the respective maximal and minimal diameters <NUM>, <NUM>, <NUM>, <NUM> remain constant along the axial length of the cutting cylinders <NUM>, <NUM>. The first and second cutting cylinders <NUM>, <NUM> comprise a first and second cutting blades <NUM>, <NUM> respectively locatable at respective leading edges thereof <NUM>, <NUM>. The first and second cutting cylinders <NUM>, <NUM> extend axially from the respective leading edges thereof <NUM>, <NUM> to respective trailing edges <NUM>, <NUM> thereof. Each helical cutting formation <NUM>, <NUM> comprise a root <NUM> which defines the minimal diameter of the respective cutting cylinder <NUM>, <NUM>, and a crest <NUM> which defines the maximal diameter thereof. The helical cutting formations <NUM>, <NUM> extend in a swept fashion along the axial length of the cutting cylinders <NUM>, <NUM> with the direction of the sweep from the leading edge <NUM>, <NUM> to the trailing edge <NUM>, <NUM> of the respective cutting cylinder <NUM>, <NUM> being either clockwise or anti-clockwise about the respective central axis thereof <NUM>, <NUM>. In the embodiment shown in the drawings, the helical cutting formations of the first and second cutting cylinders <NUM>, <NUM> extend in opposing directions such that should the helical cutting formations <NUM> of the first cutting cylinder <NUM> extend in a swept fashion in an anti-clockwise direction about its central axis <NUM>, the helical cutting formations <NUM> of the second cutting cylinder <NUM> are configured to extend in a swept fashion in the clockwise direction about the central axis <NUM> of the second cutting cylinder <NUM>. It should be understood that the first cutting cylinder <NUM> could have clockwise swept helical cutting formations with the second cutting cylinder <NUM> having opposing anti-clockwise swept helical cutting formations. These opposing directions of sweep are what create the aesthetically pleasing basket/grid/mesh appearance in the foodstuff once processed by the apparatus. The cutting cylinders <NUM>, <NUM> comprise respective outer walls <NUM>, <NUM> defined by the shape of their respective helical cutting formations <NUM>, <NUM>, the outer walls <NUM>, <NUM> defining the hollow central portions <NUM>, <NUM> thereof. In the most preferable embodiment, the sweep of helical cutting formations <NUM> of the cutters <NUM>, <NUM> are orientated at an angle of between <NUM> and <NUM> degrees relative to the axial direction of the respective cutter <NUM>, <NUM>. In the most preferred embodiment the angle of sweep of the first and second cutters <NUM>, <NUM> is matching.

The helical cutting formations <NUM>, <NUM> encourage rotation of the foodstuff and/or the cutters <NUM>, <NUM> as the foodstuff is cut by the cutters <NUM>, <NUM>.

In the embodiments shown in the drawings, the helical cutting formations <NUM>, <NUM> comprise wedge shaped (see <FIG> for example), rectangular (see <FIG> for example), or rounded (see <FIG> for example) cutting formations. In the embodiment of the drawings, each of the first and second cutters <NUM>, <NUM> comprises <NUM> to <NUM> helical cutting formations <NUM>, <NUM>. It should be noted that the skilled person would understand that various shapes of helical cutting formations could be utilised, including but not limited to rectangular or square cutting formations, without departing from the scope of the invention, and that any reasonable number of helical cutting formations may be utilised on each cutter. Typically, the first cutter <NUM> will comprise more helical cutting formations <NUM> than the second cutter <NUM>.

Rotational and or axial movement of the first and/or second cutters <NUM>, <NUM> encourages passage of the foodstuff at least partially therethrough. Alternatively, or in addition, rotational and/or axial movement of the foodstuff encourages passage of the foodstuff at least partially through the first and/or second cutters <NUM>, <NUM>. In order to cut the foodstuff, the cutters <NUM>, <NUM>, and/or the foodstuff rotates as the foodstuff is cut by the cutters <NUM>, <NUM>. This rotation can be driven or facilitated by a nondriven free rotation. In one embodiment of the apparatus, the first and/or second cutters <NUM>, <NUM> are mountable such that they are freely rotatable about their central axis <NUM>, <NUM>. Alternatively, the first and/or second cutters <NUM>, <NUM> are rotationally driven by cutter driving arrangement about their central axis <NUM>, <NUM>. The cutter driving arrangement can be a motor or other such suitable driving arrangement in engagement with one or more of the cutters <NUM>, <NUM> or with components to which the cutters <NUM>, <NUM> are mounted. In some embodiments, the first and/or second cutters <NUM>, <NUM> are rotationally fixed and the foodstuff rotates as it is cut thereby. The foodstuff may be freely rotatable as it moves through the cutters <NUM>, <NUM>, or is rotationally driven by a foodstuff driving arrangement. The foodstuff driving arrangement may, for example, comprise a plate to which the foodstuff is mounted, the plate being rotationally driven by a motor or the like. In embodiments where free rotation of the cutters and/or the foodstuff is employed, the sweep of the helical cutting formations <NUM>, <NUM> causes rotation of the cutters <NUM>, <NUM> or the foodstuff as the foodstuff travels through the cutters <NUM>, <NUM>.

In addition, in some embodiments, the first and second cutters <NUM>, <NUM> are forced at least partially through the foodstuff via movement of the first and second cutters <NUM>, <NUM> in a direction along their central axis <NUM>, <NUM> with the leading edge <NUM>, <NUM> thereof being the forward most edge during this movement. In alternative embodiments, the foodstuff is forced at least partially through the first and second cutters <NUM>, <NUM> via axial movement of the foodstuff towards and into contact with the cutters <NUM>, <NUM>. In a further embodiment, the first and second cutters <NUM>, <NUM> and the foodstuff are forced in opposing directions towards one another such that the foodstuff is forced at least partially through the first and second cutters <NUM>, <NUM>.

The first and second cutters <NUM>, <NUM> may, in some embodiments, cut completely through the foodstuff. Alternatively, the first and second cutters <NUM>, <NUM> cut partially through the foodstuff and may be rotated and/or or otherwise moved in a direction opposite to a cutting direction such that they can be removed from the partially cut foodstuff. The cutting direction is the direction in which the first and/or second cutters <NUM>, <NUM>, travels through the foodstuff as the leading edge penetrates the foodstuff and travels therethrough to form a cut therein. One or both of a reverse rotational and/or axial movement of the cutters <NUM>, <NUM> and/or the foodstuff may facilitate removal of the cutters <NUM>, <NUM> from the foodstuff.

The first and/or second cutters <NUM>, <NUM> comprise cutter mounting assemblies. In one embodiment, the first cutter <NUM> is mountable via mounting features <NUM> extending from an outer surface thereof. In the embodiment shown in the drawings, these mounting features comprise mounting flanges or tabs <NUM> which may be utilised to mount the cutter <NUM> and facilitate engagement with a cutter driving arrangement where required. In an alternative embodiment, the first cutter <NUM> is mounted via mounting brackets, a mounting plate, or a mounting tube extending from proximal the leading <NUM> or trailing edge <NUM> of the first cutter. The second cutter <NUM> is mountable via a central axle or shaft <NUM> which is coaxial with the central axis of the second cutter <NUM>. In alternative embodiments, the second cutter <NUM> is mounted via mounting brackets or a mounting plate extending from proximal the leading <NUM> or trailing edge <NUM> of the second cutter. In embodiments wherein the cutters <NUM>, <NUM> are mounted on a central axle or shaft, the helical cutting formations <NUM>, <NUM> may be formed on or attached to an exterior surface <NUM> of the shaft, as is best viewed in <FIG>. In some embodiments, the second cutter <NUM> is not fixed/mounted and is forced through the foodstuff in a freely rotating manner. IN this case, the second cutter <NUM> may pass completely through and exit the foodstuff and be reset such that it is ready to cut another portion of foodstuff.

The food processing apparatus as described above may be incorporated into a wider piece of food processing plant or machinery which may comprise further elements designed to process the foodstuff prior to or after processing by the food processing apparatus.

In use, the food processing apparatus may be utilised in a method for processing foodstuff, the method comprising the step of first cutting the foodstuff using the second cutter <NUM> such that a preliminary shape is formed, the preliminary shape having an outer diameter and an inner diameter. The method further comprising the step of cutting the preliminary shape using a first cutter <NUM> to form a final shape.

Whilst not as preferable, embodiments may exist wherein the second maximal external diameter of the second cutter <NUM> is less than or equal to the first minimal internal diameter of the first cutter <NUM>. In this case the cuts formed by the first and second cutters <NUM>, <NUM> are not overlapping and as such a thin layer of material may be left across the apertures <NUM> which may be removed in a subsequent processing step. Alternatively, material may be left in the apertures to form a final shape having continuous outer walls.

Claim 1:
A food processing apparatus for the cutting of foodstuff comprising:
a first cutting means (<NUM>) having a cross-sectional shape defining a first maximal external diameter and a first minimal internal diameter (<NUM>) about a first central axis (<NUM>);
a second cutting means (<NUM>) having a cross-sectional shape defining a second maximal external diameter (<NUM>) and a second minimal internal diameter (<NUM>) about a second central axis (<NUM>), the second maximal external diameter (<NUM>) of the second cutting means (<NUM>) being greater than or equal to the first minimal internal diameter (<NUM>) of the first cutting means (<NUM>), wherein the first and second cutting means (<NUM>, <NUM>) comprise a hollow central portion defined by a plurality of helical cutting formations (<NUM>, <NUM>) formed around their respective central axis (<NUM>, <NUM>).