Technical Field

The present invention relates to an assembly for baking an edible receptacle, such as bread in the shape of a bowl, cup or cone.

Background of the Invention

Bread bowls, being bread in the shape of a bowl are sometimes used in food serving establishments for containing a dish, as an attractive alternative to normal food serving dish. Presently, most common bread bowls are formed by baking a dome shaped bread, cutting a horizontal top portion of the bread, and hollowing the bread out manually by removing bread from the middle portion thereof. Whilst this is satisfactory in some applications, it is not satisfactory in producing a large number of bread bowls or producing edible receptacles of different shapes or sizes. Further, such bread bowls cannot be produced with consistency as to the thickness of the bread bowl walls.

Baking appliances have been proposed in the past for baking edible receptacles but none can be used in practice satisfactorily.

Object of the Invention

It is the object of the present invention to substantially overcome or at least ameliorate one or more of the above disadvantages or at least provide a useful alternative

Summary of the Invention

The present an assembly for baking an assembly for baking an edible receptacle, the assembly comprising:

a bowl having a bottom wall and a side wall extending upwardly therefrom, the bowl and the side wall defining an internal space therewithin; and

an insert having a bottom wall and a side wall extending upwardly therefrom, the side wall having a top edge, a flange formation extending from adjacent said top edge, the flange formation having a portion extending outwardly and downwardly relative to the insert side wall, the insert having at least one aperture therein adjacent the top edge; wherein the insert is sized to be received within the bowl internal space and when disposed therein, the flange formation engages an inner surface of the bowl side wall and maintains the bottom wall and the side wall of the insert spaced from the bottom wall and the side wall of the bowl to form a substantially enclosed baking cavity between the bowl and the insert with said aperture(s) providing a vent for said cavity.

The at least one aperture is preferably formed in the flange formation. Alternatively or additionally, the at least one aperture can be formed in the insert side wall adjacent the top edge.

An outer edge of the flange formation preferably engages an abutment in the inner surface of the bowl when the insert is received within the bowl. The abutment is preferably an indentation or a step formed adjacent the bowl top edge. The abutment in one embodiment is a step formed in the bowl side wall which is substantially parallel to the bowl bottom wall and spaced by a short distance from the bowl top edge.

A junction between the bowl inner surface and the flange formation is preferably substantially sealed in use. The flange formation in one embodiment includes an outwardly turned lip adjacent its outer edge. The flange formation in one embodiment includes a sealing member at its outer edge.

In one embodiment, the flange formation includes a first flange extending outwardly and downwardly from adjacent said top edge.

In the preferred embodiment, the flange formation includes a first flange extending outwardly from adjacent said top edge and a second flange extending substantially downwardly from adjacent the outer periphery of the first flange. The first flange preferably extends substantially horizontally. The second flange in one embodiment is substantially parallel to the insert side wall and in another embodiment extends vertically downwardly.

The bowl side wall preferably diverges from the bottom wall to its top edge, and insert side wall diverges from its bottom wall to its top edge. The bowl and insert bottom walls are preferably circular and their respective side walls are conical.

A portion of the flange formation is preferably disposed slightly higher than the bowl top edge when the insert is received within the bowl.

The insert sidewall in one embodiment includes a series of sections of increasing diameter from the bottom wall to its top edge.

In one embodiment, one of the insert and the bowl is made from thicker material than the other.

The present invention also provides an assembly for producing a plurality of edible receptacles, the assembly comprising:

a plurality of the baking assemblies of the above ; a tray having a number of spaced apertures therein, the apertures dimensioned to allow a respective bowl to be inserted therethrough with the bowl side wall engaging said tray aperture to retain said bowl within the tray; and

a retaining means for retaining each insert within its respective bowl.

The retaining means preferably include at least one retaining bar for extending across the inserts.

The flange formation and the bowl top edge are preferably disposed slightly higher than the tray top surface and the majority of the bowl with the insert therein extends downwardly from the tray when the bowl is received in one of the apertures of the tray.

The present invention also provides a baking tray assembly comprising: a first tray having a number of spaced bowls formed therein, each bowl having a bottom wall and a side wall extending therefrom, the bottom wall and the side wall defining an internal space therewithin;

a second tray having a number of spaced insert formations formed therein, each insert formation having a bottom wall and a side wall extending therefrom, the side wall having a top edge, a flange formation extending from adjacent said top edge, the flange formation having a portion extending outwardly and downwardly relative to the insert side wall, each insert formation having at least one aperture therein adjacent the top edge; wherein each insert is sized to be received within a respective bowl internal space when the trays are attached to each other, and when each inserts is disposed within its respective bowl, the flange formation engages an inner surface of the bowl side wall and maintains the bottom wall and the side wall of the insert spaced from the bottom wall and the side wall of the bowl to form a substantially enclosed baking cavity between the bowl and the insert with said aperture(s) providing a vent for said cavity; and

a means for retaining the second tray attached to the first tray

The present invention also provides a method of producing an edible receptacle using the assembly of any one of the above assemblies, the method comprising the steps of:

placing an amount of dough in the internal space of the bowl;

placing the insert within the bowl such that the dough is located within the cavity formed between the bowl and the insert;

securing the insert to the bowl;

allowing the dough to rise; placing the assembly in an oven to bake the edible receptacle; and

removing the insert and the edible receptacle from the bowl.

Preferably, at least an outer edge of the insert flange formation is urged toward the bowl side wall inner surface by the expanding dough during the rising and/or baking step.

Brief Description of the Drawings

Preferred forms of the present invention will now be described, by way of examples only, with reference to the accompanying drawings wherein:

Figure 1 is a top perspective view of a bowl for a baking assembly of a first preferred embodiment of the present invention;

Figure 2 is a side view of the bowl of Figure 1 ;

Figure 3 is a side perspective view of an insert for the baking assembly of the first embodiment;

Figure 4 is an inverted perspective view of the insert of Figure 3;

Figure 5 is a top perspective view of the assembled baking assembly with the insert received within the bowl;

Figure 6 is a schematic simplified top view drawing of the insert of Figure 3;

Figure 7 is a schematic simplified side cross-sectional view drawing of the insert of Figure 3;

Figure 8 is a schematic simplified side cross-sectional view drawing of the assembled baking assembly of Figure 5;

Figure 9 is a top perspective view of a plurality of the assembled baking assemblies of Figure 5 arranged in a tray;

Figure 10 is a side view of the baking assemblies in a tray shown in Figure 9;

Figure 11 is a top view of the baking assemblies in a tray with retaining bars extending across the baking assemblies;

Figure 12 is a perspective view of the baking assemblies in a tray shown in Figure 11 ;

Figure 13 shows the baking assembly after baking;

Figure 14 shows a finished bowl bread product removed from the assembly of Figure 13;

Figure 15 is a schematic cross-section of an insert according to a second preferred embodiment of the present invention; Figure 16 is a schematic side cross-sectional view of the baking assembly of the second embodiment;

Figure 17 is a schematic cross-sectional view of an insert according to a third embodiment of the present invention;

Figure 18 is a schematic cross-sectional view of a third embodiment of a baking assembly;

Figure 19 is a schematic cross-sectional view of a fourth embodiment of a baking assembly;

Figure 20 is a schematic cross-sectional view of a fifth embodiment of a baking assembly;

Figure 21 is a schematic cross-sectional view of a tray embodiment of the baking assembly; and

Figure 22 is a schematic cross-sectional view of a sixth embodiment of a baking assembly;

Detailed Description of the Preferred Embodiments

Figures 1 to 8 show a baking assembly 10 according to a first preferred embodiment of the present invention. The baking assembly 10 includes a bowl 11 and an insert 21.

The bowl 11 as shown in Figures 1, 2 and 8 includes a circular bottom wall 12 and a substantially conical side wall 13 extending upwardly from the bottom wall 12. The side wall 13 extends in a generally diverging or expanding manner from its lower end 16 to its top edge 15. The side wall 13 includes a first portion 17 extending from the lower end 16, a step second portion 14 extending outwardly from an upper end 19 of the first portion 17, and a third portion 18 extending vertically upwardly from an outer periphery 27 of the step portion 14 to the top edge 15. The step portion 14 is

substantially parallel to the bottom wall 12 and spaced by a short distance from the bowl top edge 15. The side wall 13 and the bottom wall 12 define an internal space 20 therewithin. As shown in Figures 1 and 2, the top edge 15 includes a rolled lip 36.

The insert 21 as shown in Figures 3, 4 and 7, includes a bottom wall 22 and a conical side wall 23 which extends upwardly therefrom in a generally diverging or expanding manner. The side wall 23 includes a top edge 24 from which a flange formation 47 extends. The flange formation 47 includes a first annular flange 25 which extends horizontally outwardly. A second annular flange 26 extends downwardly from an outer periphery 28 of the first flange 25 to its lower edge 29. The second flange 26 includes an outwardly turned lip 37 adjacent the lower edge 29. The first flange 25 includes four circumferentially spaced holes 31 therein.

As shown in Figures 5 and 8, the insert 21 is sized to be received within the space 20 of the bowl 11. When received therein, the lower edge 29 and/or lip 37 of the insert second flange 26 rests on the step portion 14 of the bowl side wall 13. In this position, the first flange 25 is substantially aligned with the bowl top edge 15, and preferably slightly higher than the bowl top edge 15. The respective bottom walls 12 and 22 and respective side walls 13 and 23 of the bowl 11 and the insert 21 are spaced from each other, with the first flange 25 extending toward the bowl top edge 15 and the second flange 26 extending downwardly toward the step portion 14, together forming a substantially fully enclosed baking cavity 30. The baking cavity 30 includes a base portion 30a and annular sidewall 30b extending therefrom.

In use, an amount of dough or batter is placed within the space 20 (on the base 12) of the bowl 11. The insert 21 is then placed within the bowl 11 such that the dough is now located within the cavity 30 between the bowl 11 and the insert 21. The dough/batter is then left to prove (rise) for 45 to 90 minutes as required. As the dough batter rises, the second flange 26 of the insert 21 is pushed out toward the bowl third portion 18 by the expanding dough/batter, which acts as a seal to substantially stop dough/batter from escaping though the junction between the bowl sidewall 13 and the insert lower edge 29. Any excess dough/batter is pushed upwards and out of the insert apertures 31. As the apertures 31 are at the highest point of the cavity 30, any excess dough or batter will rise up to and out of these apertures 31. The need for precise weighing of the dough/batter to be placed in the bowl 11 is not required, as any excess dough/batter will exit the cavity 30 through the apertures 31. The apertures 31 also allow the user to see when the dough has risen and is ready for baking.

When the dough is ready for baking, the baking assembly 10 is inserted into a tray 32 as shown in Figures 9 and 10. The tray 32 is a rectangular tray having a number of spaced apertures 35 therein. The apertures 35 are dimensioned to allow a bowl 11 to be inserted therethrough with the rolled lip 36 of the bowl 11 engaging the tray upper surface 38. In this position, the insert first flange 25 and the bowl top edge 15 are substantially level with, but slightly higher than, the tray top surface 38, and the majority of the bowl 11 with the insert 21 therein extends downwardly from the tray 32. In the embodiment shown in Figures 9 and 10, the tray includes three rows 39 of four apertures 35 each and thus twelve assembled bowl assemblies 10 can be inserted into the tray 32. Retaining bars 40 are then placed across the bowl assemblies 10 along each row 39, with the bars 40 engaging the insert first flanges 25. Clamps 41 are then used to retain each end of the bars 40 to the tray 32, to maintain a downward retaining force on the insert 21 to the bowl 11. The bowl assemblies 10 are rotated if required such that the apertures 31 in the first flanges 25 are not covered by the bars 40. The trays 32 having the baking assemblies 10 are then placed in a hot air circulated oven for 20 to 25 minutes baking.

Figure 13 shows a baked bread bowl product within the baking assembly 10 after baking. During the baking process, the insert second flange 26 is further pushed out by the expanding bread and stops dough/batter form escaping though the junction between the bowl sidewall 13 and the insert second flange 26. The insert apertures 31 allow steam and excess dough/batter 51 to rise up and exit out of the cavity 30. Also, any excess dough/batter 51 extending out of these apertures 31 are baked during the baking process. This provides a visual indicator to the user as to when the bread within the cavity 30 is properly baked. If no excess dough/batter has risen through an aperture 31 , the user can still see though the aperture 31 to determine whether the bread in the cavity 30 is baked. Excess dough 51 extending out of the apertures 31 are then cut off. The insert 21 is then removed from the bowl 11 and the finished bread bowl product 50 as shown in Figure 14 is removed from the bowl 11.

The preferred embodiment thus provides an assembly which produces a well shaped edible receptacle product. As the junction between the bowl sidewall 13 and the insert second flange 26 is well sealed during the proving and baking processes, dough/batter only expands upwardly and fills the cavity 30, which creates a smooth, neat finish to the upper rim of the edible product 50. The assembly does not require individual clamps between each insert and bowl, but can be modified for such clamps for one-off household use for example. The preferred embodiment thus creates a neater product, consumes less dough/batter, is practical to use in an oven and reduces labour compared to prior existing methods and devices.

Although a preferred embodiment of the present invention has been described, it will be apparent to skilled persons that modifications can be made to the embodiment shown. For example, the dimensions of the assembly 10 can be modified to create a bowl of any shape or size. Also, the bowl and insert surfaces can include a non-stick coating if desired. The baking assemblies in a tray shown in Figure 11 can also be baked in a normal hot sole oven.

In another possible modification, the bowl and/or insert can be made from transparent or translucent material which will allow viewing of the edible product being made. Also, the insert can be made from thicker material than the bowl, or vice versa. In this embodiment, the bread surface adjacent the thicker material will be baked slower than the other surface of the bread. This results in the faster baked surface being harder than the other surface. This embodiment for example may be desired in different applications, such as for soup bowls where in the inner surface is desired to be harder than the outer surface. The first flange 25 can also be formed to include a curve or an embossment design if desired.

In one possible embodiment as shown in Figure 21, a tray 60 can be provided which includes a number of the bowls 11, similar to a baking tray for muffins. A second tray 65 can then be provided which includes a number of the inserts 21 corresponding to the bowls 11. In this embodiment, portions of the tray 65 can form the first flanges 25 and the second flanges 26 extend generally downwardly therefrom. The apertures 31 can also be formed in the tray 65. After dougr^atter is placed in the bowls 11, the two trays can then be clamped together to from a plurality of the assemblies 10. This embodiment can be used in a fully automated system which places dough into the bowls, clamps the trays together with pressure and bakes the bread bowl in a sequence.

Figures 15 and 16 show a second preferred embodiment of the present invention which is substantially similar to the first embodiment apart from a few modifications. In this embodiment, the second flange 26 of the insert 21 extends vertically downwardly. The step portion 14 of the bowl 11 is shorter than in the first embodiment.

Figure 17 and 18 show a third preferred embodiment of the present invention which is also substantially similar to the first embodiment apart from a few modifications. In this embodiment, the second flange 26 of the insert 21 extends downwardly and inwardly and parallel to the insert sidewall 23. The bowl side wall 13 includes a single straight conical section 17, and the step portion 14 is formed by an indentation 14a at an inner surface thereof which is spaced from the top edge 15.

In another possible modification, the sidewalls 13 and 23 can extend vertically upwardly from the respective bottom walls 12 and 22. It is also possible for the bowl not to have an indentation or step portion, with the insert being retained in position within the bowl via the first and/or second flange only. For example, the second flange lower end can be angled to engage the inner surface of the bowl, or it can include additional engagement means such as a rubber ring for engaging the bowl inner surface. It is also possible to omit the second flange and have the peripheral edge of the first flange engage the bowl inner surface.

Figure 19 shows a fourth preferred embodiment of the present invention which is also substantially similar to the first embodiment. In this embodiment, the bowl 11 is generally similar to that shown in Figure 8 or Figure 16. The insert sidewall 23 includes a series of first to third sections 23 a, 23b and 23 c of increasing general diameter. The first section 23 a extends from the bottom wall 22 and is connected to the second section 23b via an outwardly extending first step 46a. The second section 23b is connected to the third section 23c via an outwardly extending second step 46b. The third section 23c extends to the first flange 25, with the second flange 26 extending generally downwardly therefrom.

The embodiment of Figure 19 allows for the insert 21 to be pulled from the baked bread product easier, and provides an attractive appearance.

As shown in Figure 19, the apertures 31 of the insert can alternatively be formed adjacent the top edge of the sidewall 23 shown as aperture 31a, or in the second flange 26 shown as aperture 31b. This alternative location of the apertures 31 can also be applied to the other embodiments described above. Figure 19 also shows that the first flange can be curved if desired.

Figure 20 shows a fifth preferred embodiment of the present invention which is also substantially similar to the first embodiment apart from a few modifications. In this embodiment, the flange formation 47 consists of the first flange 25 only, which extends outwardly and downwardly to the insert step portion 14 to support the insert 21 in the bowl 11.

In another embodiment, the lower edge of the first or second flange which engages the bowl can include a sealing means therewith, such as a flexible edge member for example made from rubber or plastics.

Figure 22 shows a sixth preferred embodiment of the present invention. In this embodiment, the bowl 11 is generally similar to that shown in Figure 8. The insert sidewall 23 includes first and second sections 23 a and 23b of increasing general diameter, similar to that shown in Figure 19. The first section 23 a extends from the bottom wall 22 and is connected to the second section 23b via an outwardly extending first step 46a. The second section 23b includes a number of spaced vertical formations 49 extending from the first step 46a to the top edge 24. The formations 49 can either extend into the cavity sidewall portion 30b (as protrusions) to form grooves or channels in the finished bread product 50, or it can extend away from the cavity sidewall portion 30b (as channels) to form protrusions in the finished product 50. The formations 49 allow the finished bread bowl product to be split into portions with ease.