Patent ID: 12193612

DETAILED DESCRIPTION

Various aspects of the disclosure are described more fully below with reference to the accompanying drawings, which from a part hereof, and which show specific example aspects. However, different aspects of the disclosure may be implemented in many different ways and should not be construed as limited to the aspects set forth herein; rather, these aspects are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the aspects to those skilled in the art. Aspects may be practiced as methods, systems or devices. Accordingly, aspects may take the form of a hardware implementation, an entirely software implementation or an implementation combining software and hardware aspects. The following detailed description is, therefore, not to be taken in a limiting sense.

The present disclosure relates to an apparatus and methods for forming a filled roll. The filled roll may include a sushi roll, a California roll, for example. In aspects, a filled roll is suitable for human-consumption. The apparatus may include two rods and a continuous mat. The two rods include a front rod and a back rod. In aspects, the front rod is positioned lower than the back rod for ease of placing filler ingredients and removing a filled roll from the front of the apparatus. Each rod may be in the form of a cylinder, which may be solid or hollow, and may be defined by two parallel circular ends joined longitudinally by a curved surface. The front/lower rod and the back/upper rod may have the same diameter. In one example, the continuous mat may be formed by joining a first edge and an opposing second edge along a width of a rectangular sheet of matting, where a width of the continuous mat corresponds to the width of the rectangular sheet. In another example, the continuous mat may be formed by a variety of methods including but not limited to injection molding and 3-D printing. The width of an inner surface of the continuous mat may contact at least a portion of the longitudinal curved surface of each rod and may be operable to connect the two rods. Further, the continuous mat may form a longitudinal pocket between opposing proximal longitudinal surfaces of the two rods. Fillers, such as rice, strips of vegetables or fish, and the like, may be placed onto a wrapper within the longitudinal pocket of the continuous mat.

The rods may be rotated by manually actuating at least one circular end of one of the rods around its axis, e.g., the back/upper rod in a clockwise direction. In aspects, by rotating one rod, the continuous mat causes the other rod to rotate in the same direction around its axis. As the rods rotate about their axes, the fillers are compressed and encircled by the wrapper. In aspects, the wrapper may surround the fillers on at least a longitudinal curved surface of the roll, with circular ends of the roll being open to expose the fillers. To eject the filled roll, at least one rod is actuated in an opposite direction of the other rod, e.g., the back/upper rod clockwise and the front/lower rod counterclockwise. In this way, gears or other actuating members are unnecessary, promoting a simple design with few parts that reduces financial and efficiency costs associated with manufacture, assembly, maintenance and cleaning of the apparatus.

As detailed herein, the present disclosure describes an apparatus that addresses the issue of conveniently forming an edible roll with a simple mechanism that does not require use of gears or shifting of the two rods. The apparatus includes a front/lower rod, a back/upper rod, and a continuous mat, which is in contact with at least distal longitudinal surfaces of both rods to connect the two rods. The continuous mat may have a uniform width and thickness and may loosely wrap around the two rods, forming a longitudinal pocket between the two rods. To form the longitudinal pocket, the continuous mat may hang down between the two rods at a depth that is greater than a distance between the two rods. In aspects, the depth of the longitudinal pocket does not extend to touch an interior base of the apparatus.

FIG.1illustrates an overview of an example apparatus for forming a filled roll in accordance with aspects of the present disclosure. Apparatus100may represent an apparatus for forming a filling roll, e.g., a sushi roll.

The apparatus100includes a left wall102A, a right wall102B, and a base114. The left wall102A and the right wall102B are vertical walls and are positioned in parallel. Each of the left wall102A and the right wall102B include two holes for installing rods. The apparatus further includes a front rod104(or a shaft) and a back rod106(or a shaft). In aspects, the front rod104extends through a lower hole having a diameter in the left wall102A and in the right wall102B. A diameter of the lower holes may be based on a diameter of the front rod104, e.g., a diameter slightly larger than the diameter of the front rod104such that the front rod104is able to rotate but does not substantially move laterally or vertically within the hole. O-shaped rings (110A and110B) may be attached to the front rod104on an exterior side of the left wall102A and the right wall102B to prevent the front rod104from sliding horizontally through the lower holes in the walls. Similarly, the back rod106extends through an upper hole of a diameter in the left wall102A and in the right wall102B. A diameter of the upper holes may be based on a diameter of the back rod106, e.g., a diameter slightly larger than the diameter of the back rod106such that the back rod106is able to rotate but does not substantially move laterally or vertically within the hole. O-shaped rings (112A and112B) may be attached to the back rod106on the exterior side of the left wall102A and the right wall102B to prevent the back rod106from sliding horizontally through the upper holes in the walls.

A continuous mat108wraps around the two rods. In aspects, the front rod104and the back rod106are freely rotatable. By manually actuating at least one circular end of one of the rods around its axis, e.g., the back/upper rod in a clockwise direction, the continuous mat causes rotational forces on the other rod to rotate in the same direction around its axis. While not shown inFIG.1, one or both ends of the front rod104and/or the back rod106may be coupled to a handle or handles for actuating rotation of the at least one rod. In aspects, the left wall102A, the right wall102B, the base114may be made of a translucent material, such as acrylic and other polymer plastic.

As noted above, the continuous mat108forms a longitudinal pocket116between the two rods. The longitudinal pocket116may receive fillings and a wrapper (e.g., seaweed nori). The longitudinal pocket116is used for forming a filled roll as the front rod104and the back rod106rotate as the continuous mat108grips the exterior longitudinal surfaces of the rods. In aspects, a depth of the longitudinal pocket is at least a distance between the two rods. In some other aspects, the depth may depend on a diameter of one or both of the two rods. The depth may be within a predetermined distance, determined based at least on a diameter of one or both of the two rods, for example. In aspects, an inner surface of an upper portion120of the continuous mat108does not touch an inner surface of a lower portion118of the continuous mat108at the depth of the longitudinal pocket116. Additionally, the depth of the longitudinal pocket may be determined such that the continuous mat108does not touch an inner surface of the base114of the apparatus. The continuous mat108may be made of food-grade silicone, for example.

In aspects, the continuous mat may provide surface characteristics where the continuous mat does not adhere to the filling (e.g., cooked rice or the sheet of seaweed) or the rods but does not slip when contacting the rods. In aspects, when a rotational force is applied to at least one rod, friction prevents the continuous mat108from slipping against the rods. In aspects, the gripping surface of the continuous mat reduces a chance of the continuous mat from slipping on the rods when the rods rotate beneath the continuous mat, based a force that is parallel to the endless sheet and in tangent to the surface of the rods, particularly when the filling is placed in the longitudinal pocket. The characteristics of the continuous mat (e.g., gripping the rods without adhering to the filling or the rods) helps forming the roll as the rods rotate. In aspects rotating one of the rods causes the other rod to rotate based on a friction of the wrapped endless (continuous) mat caused at least by a weight of the filling placed in the longitudinal pocket. Use of the continuous mat removes the need of using a set of gears to keep the driver rod and the driven rod engaged. Without use of the gears, the apparatus according to the present disclosure is easier to clean. The continuous mat may be in a form including but not limited to a mesh. The mesh silicone mat may grip the rods without adhering to the filling (rice, for example) or the rods.

In aspects, the O-rings110A-B and112A-B are removable for removing the rod from the apparatus by sliding the rods through the holes (111A,111B,113A, and113B) on the left side panel and the right side panel. The continuous mat108is removable from the apparatus by removing the rods for cleaning.

In aspects the set of rods may be exchanged with another set of rods with a different thickness or diameter. Use of a pair of rods with a smaller diameter increases a distance between the pair of rods, thereby increasing a size of the longitudinal pocket116for creating a thicker roll. Use of a pair of rods with a larger diameter causes the longitudinal pocket116to be smaller, for creating a thinner roll. In the case of variable rod sizes, the holes111A-B and113A-B may be provided with a diameter for accommodating the largest-diameter rods. To install a set of rods with a smaller diameter, washers (not shown in figures) may be placed in the respective holes to decrease the hole size to fit the set of smaller-diameter rods.

In aspects, holes and slots on the apparatus100may be created using a laser cutter for accuracy and for ease of manufacturing. The left wall102A, the right wall102B, and the base114may be glued or otherwise adhered at respective joining edges. Alternatively, the three parts may be made of one piece that is bent at two locations, forming the left wall102A, the right wall102B, and the base114to reduce a number of parts in the apparatus.

As should be appreciated, the various methods, devices, applications, features, etc., described with respect toFIG.1are not intended to limit the apparatus100to being performed by the particular applications and features described. Accordingly, additional controller configurations may be used to practice the methods and systems herein and/or features and applications described may be excluded without departing from the methods and systems disclosed herein.

FIG.2illustrates an example apparatus in an operable state from a second perspective view point in accordance with aspects of the present disclosure. Apparatus200may represent an apparatus for forming a filling roll, a sushi roll for example. The second view point is from an upper right position behind the apparatus.

FIG.3illustrates an example apparatus in an operable state from an upper front view point in accordance with aspects of the present disclosure. Apparatus300may represent an apparatus for forming a filling roll, a sushi roll for example. The third view point is from a in front of and slightly above the apparatus.

FIG.4illustrates an example apparatus in an operable state from a right-side view point in accordance with aspects of the present disclosure. Apparatus400may represent an apparatus for forming a filling roll, a sushi roll for example. The fourth view point is from the right side of the apparatus. The circle122referenced within the longitudinal pocket116indicates an exemplar position of a filled roll in the longitudinal pocket116of the apparatus400.

In some aspects, the back rod106may be positioned higher than the front rod104. That is, at least a height (H1) of the back rod124is greater than a height (H2) of the front rod104. In some other aspects, a distance (D1) from the lowest longitudinal surface of the back rod106may be the same or less than the height (H2) of the front rod104(as shown, D1 is less than H2). The vertical positioning of the back rod106and the front rod104enables ease of receiving the filling from the front of the apparatus400. The vertical positioning of the rods and the longitudinal pocket116formed there between prevents the filling from spilling out when rotating the rods to compress the filling within the wrapper. Once the filled roll is formed, the vertical positioning further enables the filled roll to be easily removed from the longitudinal pocket116by simply reversing a rotation (e.g., counterclockwise) of the lower/front rod104while maintaining a clockwise rotation of the upper/back rod106.

FIG.5illustrates an example apparatus in an operable state from an enlarged left-side view point in accordance with aspects of the present disclosure. The enlarged drawing indicates left ends of the front rod104and the back rod106, for example. The circle122referenced within the longitudinal pocket116indicates an exemplar position of a filled roll in the longitudinal pocket116of the apparatus500.

FIG.6illustrates an example apparatus and cover from the first perspective view point in accordance with aspects of the present disclosure.FIG.6includes a cover604and an apparatus600. In aspects, the cover604may comprise a top624, a front wall626and a back wall606. In aspects, the top624of cover604may include a knob602for raising and lowering cover604onto apparatus600.

In some examples, the back wall606may comprise two portions, a fixed portion606A and a hinged portion606B. In this example, the hinged portion606B may be affixed to the top624and removably adjoined to left wall102A and right wall102B of the apparatus600. Further in this example, the fixed portion606A may be removably adjoined to base114, left wall102A, and right wall102B. In aspects, the cover604may comprise protruding members (or pegs) for removably adjoining the cover to the apparatus600. Continuing with the example above, protruding member608on the right side of hinged portion606B of cover604fits into a hole612B of the right wall102B of apparatus600. While not shown, a protruding member on the left side of hinged portion606B may fit into a hole612A on the left wall102A of apparatus600. In aspects, the hole612A and the hole612B may be sized and shaped to enable rotation of the protruding members within the holes. The hole612A and the hole612B may be circular shaped, for example. This way, by rotating the protruding members clockwise within the holes, the cover604may swing open to enable access to front rod104and back rod106of apparatus600for use or cleaning.

Continuing with the above example, fixed portion606A includes a protruding member610on a right edge that may fit into a hole614on right wall102B. Additionally, fixed portion606A may include another protruding member (not shown) along a left edge for fitting in a hole (not shown) in left wall102A. In still further aspects, fixed portion606A may include protruding member618B for fitting into hole622of base114. In aspects, the number of protruding members and corresponding holes described herein is not limited to two; there may be none, one, or more. In aspects, fixed portion606A may act as a stopper for hinged portion606B such that an angle of about 90 degrees is formed when hinged portion606B rotates clockwise to rest against fixed portion606A, thereby maintaining cover604in an open position.

In other examples, back wall606may comprise a single portion affixed to top624and removably adjoined to base114. In aspects, the cover604and the fixed back wall606are in one piece to be placed over the apparatus600. The front wall626and the back wall606, respectively, include protruding members (or pegs) (616A-B and618A-B) that fit into holes on the base114. The protruding member616A fits into a hole620A; the protruding member616B fits into a hole620B; the protruding member618A fits into a hole (not shown) on the base114; and the protruding member618B fits into a hole622.

FIG.7illustrates an example covered apparatus in an inoperable state for storage from the first perspective view point in accordance with aspects of the present disclosure. In aspects, the front wall626, top624, and back wall606of cover604enclose the apparatus. The cover604may be made of a material such as acrylic or other polymer plastic. In some other aspects, either or both of the cover604and the base114may be made of materials such as bamboo or stainless steel. The cover604may be manufactured by bending a single sheet of the material at two locations using thermal or other methods, forming the front wall626, top624, and back wall606(or hinged portion606B). The cover604may include an affixed knob602on the top624by a method including but not limited to a glue or acrylic screw into a hole created by a laser cut.

In aspects, manufacturing of the parts of the apparatus may include the following: 1) bend a single sheet of material (e.g., on a heat strip) to form the bottom base plate (base114), left wall102A and right wall102B; 2) cut the base114, left wall102A and right wall102B into individual pieces of material; 3) laser cut slots and holes in the base114and left and right walls102A for insertion of rods and protruding members-B; 4) when formed of individual parts, glue the left and right walls102A-B to the base114; 5) cut rods to size; 6) adhere (e.g., using an adhesive such as glue) opposing ends of the mat to form the continuous mat; 7) cut material for cover604including tabs (the protruding members) and a hole to receive knob602using a laser cutter; for example. Thermal bending of the parts reduces a number of parts of the apparatus, simplifies the manufacturing process by eliminating the steps of using glues, and reduces manufacturing defects caused by errors in the gluing step.

In aspects, assembly of the apparatus700may include inserting the two rods104,106through side holes (e.g., holes111A-B and113A-B) in the left and right walls102A-B and through the continuous mat108. Assembly of the cover over the apparatus may include steps of: 1) snapping the front wall626of the cover604into slots in a front edge of the base114; and 2) snapping the back wall606of the cover104into a rear edge of the base114; and 3) screwing the knob602into top624of the cover604.

FIG.8illustrates an example method of forming a filled roll in accordance with aspects of the present disclosure. A general order of the operations for method800is shown inFIG.8. Generally, the method800starts with a receive operation804and ends with an rotate operation812. The method800may include more or fewer steps or may arrange ordering of the steps differently than those shown inFIG.8. The method800is directed to forming a filled roll. The method800can be executed by using an apparatus for forming a filled roll. Hereinafter, the method800shall be explained with reference to the systems, component, devices, modules, methods, etc., described in conjunction withFIGS.1-7.

At receive operation804, a filling is received into a longitudinal pocket formed by a continuous mat between a front rod and a back rod of an apparatus. The filling may include rice, vegetables, and slices of fish or egg, for example. In aspects, a weight of the filling in the longitudinal pocket increases a tension of the continuous mat, increasing a grip of the continuous mat on the front rod and the back rod. The increased tension of the continuous mat may improve the gripping characteristics of the continuous mat.

At rotate operation806, the back rod may be rotated clockwise or counterclockwise (e.g., from a right-side viewpoint of the apparatus). Based on the continuous mat gripping both the back rod and the front rod, the front rod rotates in the same direction (e.g., clockwise or counterclockwise) as the back rod. In aspects, the rotation may be caused when an operator manually rotates the back rod by contacting one or both ends of the back rod. The rotate operation806causes the filling to be compressed inside the longitudinal pocket. In aspects, continuing rotate operation806causes a roll of filling to be formed within the longitudinal pocket of the continuous mat. The continuous mat may be configured to grip the rods while not adhering to the filling. During the rotate operation806, the filling may also rotate within the longitudinal pocket to form a roll. In some aspects, both the front rod and the back rod may be rotated in the same direction (clockwise or counterclockwise), causing the filling to rotate within the longitudinal pocket. The characteristics of the continuous mat may enable gripping the rods without adhering to the filling, sticky-rice, for example. In this way, the filling is prevented from overflowing from and/or adhering to the longitudinal pocket. The user may stop the rotate operation806operation when the filling has formed a roll inside the longitudinal pocket.

At receive operation808, the apparatus may receive a wrapper sheet (e.g., a nori seaweed sheet). In aspects, the receive operation808receives the wrapper vertically, in a space between the rolled filling (or the formed roll without the wrapper) and a portion of the continuous mat gripping the front rod.

At rotate operation810, the back rod may be rotated clockwise or counterclockwise (e.g., from a right-side viewpoint of the apparatus). The rotate operation810causes the wrapper to be inserted into the longitudinal pocket along the continuous mat between the rolled filling and the continuous mat. Continuing the rotate operation810may cause the wrapper to completely wrap around the filling to form a filled roll.

At counter rotate operation812, the front rod may be rotated in an opposite direction from the back rod. That is, as the back rod is rotated clockwise (or counterclockwise), the front rod is rotated counterclockwise (or clockwise, respectively). That is, the direction of the counter rotate operation812is a reverse rotation of the rotate operations806and810. In aspects, the operator may grip one or both ends of the front rod for the counter rotate operation812while gripping one or both of the back rod for rotate operation810. The counter rotate operation812may cause the wrapped roll to rise from the longitudinal pocket for easy removal of the wrapped roll from the apparatus.

As should be appreciated, operations804-812are described for purposes of illustrating the present methods and systems and are not intended to limit the disclosure to a particular sequence of steps, e.g., steps may be performed in different order, additional steps may be performed, and disclosed steps may be excluded without departing from the present disclosure.

The operating environment may be a manual operation while the apparatus is placed on a table or a desk. In some other aspects, the operation environment may be an automated operation where at least one of the rods attaches to a motor, for example. The description and illustration of one or more aspects provided in this application are not intended to limit or restrict the scope of the disclosure as claimed in any way. The aspects, examples, and details provided in this application are considered sufficient to convey possession and enable others to make and use the best mode of claimed disclosure. The claimed disclosure should not be construed as being limited to any aspect, for example, or detail provided in this application. Regardless of whether shown and described in combination or separately, the various features (both structural and methodological) are intended to be selectively included or omitted to produce an embodiment with a particular set of features. Having been provided with the description and illustration of the present application, one skilled in the art may envision variations, modifications, and alternate aspects falling within the spirit of the broader aspects of the general inventive concept embodied in this application that do not depart from the broader scope of the claimed disclosure.

As will be understood from the foregoing disclosure, one aspect of the technology relates to an apparatus for forming a filled roll of food. The apparatus comprises: a first wall; a second wall; a base, wherein the first wall and the second wall adjoin the base along opposing side edges of the base; a first rod and a second rod, wherein a first end of each rod extends horizontally through the first wall and a second end of each rod extends horizontally through the second wall, wherein the first rod and the second rod are about parallel to the base, wherein the first rod is positioned forward of the second rod by a predetermined distance, and wherein the first rod is positioned lower vertically than the second rod; a continuous mat wrapping around the first rod and the second rod, wherein the continuous mat grips without adhering to an external longitudinal surface of the first rod and the second rod, and wherein when the first rod is rotated in a first direction the continuous mat causes the second rod to rotate in the first direction; and a longitudinal pocket formed by the continuous mat between the first rod and the second rod, wherein rotating the first rod in the first direction causes a filling within the longitudinal pocket to form a roll, and wherein rotating the second rod in a second direction opposite the first direction causes the roll to be ejected from the longitudinal pocket.

In the apparatus, the first wall and the second wall adjoin the base based on at least one of: gluing, interlocking members, hinges, bending, molding, and printing. The first wall and the second wall adjoin the base respectively forming an angle of about 90 degrees. The first wall and the second wall are oriented vertically, and wherein the base is oriented horizontally. The apparatus further comprises a removable cover for storage, removably adjoining the left wall and the right wall along top edges respectively, and removably adjoining the base along a front edge and a rear edge of the base. The apparatus further comprises a removable back panel, the removable back panel including a first protruding member and second protruding member, the first protruding member configured to extend into a first hole on the left wall, the second protruding member configured to extend into a second hole on the right wall, and the removable back panel removably adjoining the base along a back edge of the base. The apparatus further comprises a removable cover for storage, removably adjoining the left wall and the right wall along top edges respectively, removably adjoining the base along a front edge, and removably adjoining the removable back panel along a top edge of the removable back panel. The removable cover includes a front wall, a top, and a back wall including vertical edges, the top including a handle, the back wall including a first protruding member and a second protruding member along the vertical edges, the first protruding member extending through a first hole on the left wall, the second protruding member extending through a second hole on the right wall, and the cover being rotatable at the protruding members for opening and closing the cover on the apparatus. The first direction of rotation relates to a clockwise rotation of the first rod from a view point on the right side of the apparatus, and the second direction of rotation relates to a counterclockwise rotation of the first rod from the view point.

In another aspect, the technology relates to a system for forming a filled roll food. The system comprises: a first wall; a second wall; a base, wherein the first wall and the second wall adjoin the base along opposing side edges of the base; a first rod and a second rod, wherein a first end of each rod extends horizontally through the first wall and a second end of each rod extends horizontally through the second wall, wherein the first rod and the second rod are about parallel to the base, wherein the first rod is positioned forward of the second rod by a predetermined distance, and wherein the first rod is positioned lower vertically than the second rod; a continuous mat wrapping around the first rod and the second rod, wherein the continuous mat grips without adhering to an external longitudinal surface of the first rod and the second rod, and wherein when the first rod is rotated in a first direction the continuous mat causes the second rod to rotate in the first direction; and a longitudinal pocket formed by the continuous mat between the first rod and the second rod, wherein rotating the first rod in the first direction causes a filling within the longitudinal pocket to form a roll, and wherein rotating the second rod in a second direction opposite the first direction causes the roll to be ejected from the longitudinal pocket.

In the system, the first wall and the second wall adjoin the base based on at least one of: gluing, interlocking members, hinges, bending, molding, and printing. The first wall and the second wall adjoin the base respectively forming an angle of about 90 degrees. The first wall and the second wall are oriented vertically, and wherein the base is oriented horizontally. The system further comprises a removable cover for storage, removably adjoining the left wall and the right wall along top edges respectively, and removably adjoining the base along a front edge and a rear edge of the base. The system further comprises a removable back panel, the removable back panel including a first protruding member and second protruding member, the first protruding member configured to extend into a first hole on the left wall, the second protruding member configured to extend into a second hole on the right wall, and the removable back panel removably adjoining the base along a back edge of the base; and a removable cover for storage, removably adjoining the left wall and the right wall along top edges respectively, removably adjoining the base along a front edge, and removably adjoining the removable back panel along a top edge of the removable back panel. The removable cover includes a front wall, a top, and a back wall including vertical edges, the top including a handle, the back wall including a first protruding member and a second protruding member along the vertical edges, the first protruding member extending through a first hole on the left wall, the second protruding member extending through a second hole on the right wall, and the cover being rotatable at the protruding members for opening and closing the cover on the apparatus.

In another aspect, the technology relates to a method of forming a filled roll food. The method comprises receiving a filling into a longitudinal pocket formed by a continuous mat wrapped around a first rod and a second rod, wherein a first end of each of the first rod and the second rod extends horizontally through the first wall and a second end of the first rod and the second rod extends horizontally through the second wall, wherein the first rod and the second rod are about parallel to the base, wherein the first rod is positioned forward of the second rod by a predetermined distance, and wherein when the first rod is positioned lower vertically than the second rod, wherein the continuous mat grips without adhering to an external longitudinal surface of the first rod and the second rod; rotating the first rod in a first direction causing the filling within the longitudinal pocket to form a roll; and rotating the second rod in a second direction opposite the first direction causes the roll to be ejected from the longitudinal pocket. T the first wall and the second wall adjoin the base based on at least one of: gluing, interlocking members, hinges, bending, molding, and printing. The first wall and the second wall adjoin the base respectively forming an angle of about 90 degrees. The first wall and the second wall are oriented vertically, and wherein the base is oriented horizontally.

Any of the one or more above aspects in combination with any other of the one or more aspect. Any of the one or more aspects as described herein.