DESCRIPTION

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Patent Application Serial No. 13/195,469 filed 1 August 2011, and U.S. Provisional Patent Application Serial No. 61/375,419 filed 20 August 2010 each of which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

[0002] The present invention relates to a food punching device, and more particularly, to a food punching device adapted to punch food sheet products into certain shapes or to provide borders along food sheet products having certain patterns.

BACKGROUND OF THE INVENTION

[0003] When preparing food, such as during baking, it is often necessary to cut food sheet products into particular shapes, or to provide a decorative border to a food sheet product. For example, rolled gum paste sheets, gum paste and fondant blends, extruded gum paste sheets and fondant are all useful in decorating baked goods, such as cakes, and are provided as a generally flat-sheet. Currently, a baker, or other food preparer, has few options to produce repeatable designs in food sheet products. One way that designs may be created is to simply free hand the design, however, this is not consistently repeatable. Another option is to use a cookie cutter, but such a product requires the baker to handle the food sheet product more than desired, and cookie cutters are not well suited for use with food sheet products having a relatively hard consistency. Additionally, it is difficult to create a border pattern on the food sheet product with existing baking tools.

[0004] The present invention is provided to solve the problems discussed above and other problems, and to provide advantages and aspects not previously provided. A full discussion of the features and advantages of the present invention is deferred to the following detailed description, which proceeds with reference to the accompanying drawings. SUMMARY OF THE INVENTION

[0005] According to one embodiment, a food punch assembly for a food sheet comprises a base, a lid, a die and a punch. The base has a food receiving surface, and a die receiving opening. The die receiving opening is formed in the food receiving surface. The lid has a punch receiving opening disposed in corresponding alignment with the die receiving opening. The lid is hingedly attached to the base and is movable between an open position and a closed position relative to the base. The lid has an actuatable punch receiving surface. The actuatable punch receiving surface is biased to a first inactive position and movable to a second activated position. The punch at least partially resides in the punch receiving opening of the lid. The punch having a punch protrusion configured to correspond with a die opening when the lid is in the closed position and the punch receiving surface is in the second activated position. The die has an opening for receiving the punch protrusion. The die at least partially resides in the die receiving opening of the base.

[0006] According to another embodiment, a punch base assembly for a food punch for a food sheet comprises a base and a lid. The base has a food receiving surface and a die receiving opening formed through the food receiving surface. The base further has at least one lid aligning protrusion that projects upwardly from the food receiving surface. The lid has a top surface and a punch receiving opening that passes through the top surface. The lid further has an outer sidewall and an inner sidewall that projects downwardly from the top surface. The inner sidewall is in communication with the punch receiving opening. An actuatable punch receiving surface has a first position and a second position. The actuatable punch receiving surface is disposed between the inner sidewall and the outer sidewall of the lid. The actuatable punch receiving surface is disposed proximate the top surface in the first position. The lid is adapted to move between an open position and a closed position relative to the base. The lid hingedly connects to the base.

[0007] According to a further embodiment, a food punch and die set for a punch base assembly comprises a first die and a first punch. The first die has an opening formed

therethrough. The opening has a first die pattern formed therein. The first punch has a generally flat top surface. A generally continuous sidewall projects downward from the top surface. At least one punch base assembly projection projects downward from the top surface. The at least one punch base assembly projection is positioned outward of the generally continuous sidewall. A punch protrusion is disposed proximate a bottom of the generally continuous sidewall. The punch protrusion has a first punch pattern. The first punch pattern is adapted to be received by the opening of the die having the first die pattern. The first punch pattern is complementary to the first die pattern.

[0008] According to one process, a method of punching a pattern into a food sheet is disclosed. A punch base assembly for a food punch is provided. The punch base assembly comprises a base that has a food receiving surface and a die receiving opening. The punch base assembly further comprises a lid that has a punch receiving opening and an actuatable punch receiving surface that has a first position and a second position. The lid connects to the base with a hinge. A food sheet product is provided. A first die is inserted into the die receiving opening of the punch base assembly. A first punch is inserted into the punch receiving opening of the punch base assembly. The food sheet is placed on the food receiving surface of the punch base assembly. The lid moves from the open position to the closed position. The actuatable punch receiving surface moves from the first position to the second position. The punch passes through the food sheet with the movable punch receiving surface in the second position.

[0009] Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:

[0011] FIG. 1 is a perspective view of a food punch assembly in a closed position according to one embodiment;

[0012] FIG. 2 is a perspective view of the food punch assembly of FIG. 1 in an open position;

[0013] FIG. 3 is a perspective view of the food punch assembly of FIG. 1 with the punch and die removed from the punch base;

[0014] FIG. 4 is a perspective view of a food punch assembly according to another embodiment;

[0015] FIG. 5 is a perspective view of a food punch assembly according to another embodiment; [0016] FIG. 6 is a perspective view of a die, a punch, and a punch cover for use with a food punch assembly;

[0017] FIG. 7 is a side view of the punch of FIG. 6;

[0018] FIG. 8 is a sectional view of an assembly formed from the die, the punch, and the punch cover of FIG. 6;

[0019] FIG. 9 is a top perspective view of an edge die, an edge punch, and a punch cover according to a further embodiment; and

[0020] FIG. 10 is a bottom perspective view of the edge die, the edge punch, and the punch cover of FIG. 9.

[0021] The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention.

DETAILED DESCRIPTION

[0022] While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an

exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.

[0023] According to one embodiment of the present invention, as shown in FIGs. 1-3, a food punch assembly 10 is provided. The food punch assembly 10 comprises a punch base assembly 12 having a base 14 and a lid 16. The lid 16 hingedly connects to the base 14 via a hinge 18.

[0024] The base 14 has a die receiving opening 20. The die receiving opening 20 has a die securing groove 22. The die securing groove 22 is adapted to receive a portion of a die 40 used with the food punch assembly 10. The die securing groove 22 is generally disposed proximate a periphery of the die receiving opening 20. The base 14 additionally comprises a food receiving surface 24. The food receiving surface 24 is generally flat to allow the food sheet product to rest on the food receiving surface 24.

[0025] The base 14 additionally has a pair of hinge protrusions 26a, 26b. The hinge protrusions 26a, 26b extend upward from the food receiving surface 24. The hinge protrusions 26a, 26b each have a through hole to receive a hinge pin 27 to connect the base 14 to the lid 16 of the base assembly 12. Lid aligning protrusions 28a, 28b also protrude upward from the food receiving surface 24. The lid aligning protrusions 28a, 28b assist in positioning the lid 16 relative to the base 14 as the lid 16 pivots about the hinge 18. It is also contemplated, according to another embodiment, that lid aligning recesses may be provided on the base 14 to align protrusions on the lid 16 as the lid 16 pivots about the hinge 18.

[0026] The lid 16 has a punch receiving opening 30 adapted to receive a punch 50. The punch receiving opening 30 passes through the lid 16. The lid 16 has a top surface 32 through which the punch receiving opening 30 passes. The punch receiving opening 30 defines an inner sidewall 34 of the lid 16. The lid 16 also has an outer sidewall 35. The inner and outer sidewalls 34, 35 descend from the top surface 32 of the lid 16.

[0027] The top surface 32 of the lid 16 has a peripheral ledge 36. The peripheral ledge 36 extends downward from the top surface 32 and the peripheral ledge 36 extends beyond the outer sidewall 35.

[0028] The inner and outer sidewalls 34, 35 of the lid 16 terminate at a base facing surface

37 of the lid 16. The base facing surface 37 faces the food receiving surface 24 of the base 14 when the lid 16 is in the closed position, as shown in FIG. 1. It is contemplated that in some embodiments a gap will exist between the base facing surface 37 and the food receiving surface 24.

[0029] An actuatable punch receiving surface 38 is provided in the top surface 32 of the lid 16. The actuatable punch receiving surface 38 is disposed between the inner sidewall 34 and the outer sidewall 35 of the lid 16. The actuatable punch receiving surface 38 is vertically moveable between a first position, and a second position. That is, the actuatable punch receiving surface

38 moves from the first position proximate the top surface 32 to a second position proximate the base facing surface 37. The actuatable punch receiving surface 38 is biased to the first position by a biasing device. The biasing device may take a number of forms, including a spring(s), a polymeric foam, a gas strut(s), a hydraulic shock(s), or the like. It is contemplated that at least one spring will be a commonly utilized biasing device to position the moveable punch surface 38 to the first position. The biasing device may be compressed by applying a force to the actuatable punch receiving surface 38 allowing the actuatable punch receiving surface 38 to move to the second position.

[0030] The lid 16 additionally comprises a plurality of hinge connectors 39a-39c. The hinge connectors have an opening formed therethrough. The hinge connectors 39a-39c of the lid 16 are adapted to be positioned proximate the hinge protrusions 26a, 26b of the base 14. The hinge pin 27 passes through the hole of the hinge protrusions 26a, 26b and the opening of the hinge connectors 39a-39c to hingedly connect the lid 16 to the base 14 of the punch base assembly 12.

[0031] The die 40 used with the punch assembly 10 has a top surface 42. A sidewall 44 projects downward from the top surface 42 of the die 40. The sidewall 44 may be set in a distance from a periphery of the top surface 42, or may be generally aligned with the periphery of the top surface 42. The sidewall 44 is adapted to be received by the die securing groove 22 of the base 14 of the punch base assembly 12. The sidewall 44 creates a press fit with the die securing groove 22. The top surface 42 of the die 40 generally aligns with the food receiving surface 24 of the base 14.

[0032] An opening 46 is formed through the top surface 42 of the die 40. The opening 46 is sized and shaped to receive a protrusion 56 of the punch 50. The opening 46 allows the food sheet that is cut by the punch 50 to be easily removed from the food punch assembly 10. The opening 46 allows the cut food shape to pass through the base 14 to be retrieved after moving the base 14.

[0033] The die 40 may additionally comprise an alignment protrusion 48. The alignment protrusion 48 projects upwardly from the top surface 42 of the die 40. The alignment protrusion 48 is adapted to help align the food sheet with respect to the die 40, as a user may place an edge of the food sheet proximate the alignment protrusion 48. The alignment protrusion 48 may also form a spacer to keep the lid 16 a predetermined distance from the base 14.

[0034] The punch 50 has a generally flat top surface 52. The generally flat top surface 52 projects laterally to an edge 54. The edge 54 is adapted to be positioned proximate the peripheral ledge 36 of the lid 16 when the actuatable punch receiving surface 38 is in the second position.

[0035] A continuous sidewall 53 projects downward from the generally flat top surface 52. The continuous sidewall 53 is sized and shaped to be received by the punch receiving opening 30 of the lid 16. The continuous sidewall 53 of the punch 50 is disposed proximate the inner sidewall 34 of the lid 16. The continuous sidewall 53 interacts with the inner sidewall 34 of the lid 16 to orient the punch 50 relative to the lid 16.

[0036] The punch 50 additionally comprises a plurality of punch base assembly projections 55. The punch base assembly projections 55 project downward from the generally flat top surface 52 of the punch 50. The punch base assembly projections 55 are adapted to allow the punch 50 to interact with the actuatable punch receiving surface 38 of the lid 16, such that a bottom side of the generally flat top surface 52 is proximate the top surface 32 of the lid 16. Thus, the height of the punch base assembly projections 55 are determined by the distance the actuatable punch receiving surface 38 of the lid 16 travels to reach the second position. While the punch base assembly projections 55 are shown as being separate projections, it is contemplated that a singe continuous punch base assembly projection may be provided, or that a discontinuous punch base assembly projection may be provided.

[0037] A punch protrusion 56 also projects downward from a lower surface 57 of the punch 50. The lower surface 57 being provided at the bottom of the continuous sidewall 53. The punch protrusion 56 is adapted to pass through a food sheet to cut a portion of the food sheet to the shape of the punch protrusion 56. As shown in FIGs. 1-3, the punch protrusion 56 has a shape to cut a generally circular shape into the food sheet. It is contemplated that the punch protrusion 56 may have a wide variety of other shapes to cut the food sheet into other shapes such as polygonal shapes, elliptical shapes, elongated shapes, star-like shapes, or the outline of objects, such as, for example, a flower, a bell, a bird, a person, or the like. Thus, almost any shape may be applied to the food sheet by the punch protrusion 56 of the punch 50.

[0038] An opening 58 is also formed in the punch 50. The opening 58 is disposed inward of the punch protrusion 56. The opening allows the food sheet product to be cut by the punch protrusion without overly deforming the food sheet product at a distance away from a location where the punch protrusion 56 contacts the food sheet product.

[0039] The food punch assembly 10 thus provides a removable die 40 and a removable punch 50 to allow for alternative designs to be punched into the food sheet. The removable die 40 and the removable punch 50 may be inserted into a punch base assembly 12, thereby allowing a single punch base assembly 12 to be utilized as part of a food punch assembly 10 that can provide a variety of punch designs into a food sheet. Sets of removable punches 50 and removable dies 40 may be provided in order to allow multiple designs to be made using the food punch assembly 10. These sets of removable punches 50 and removable dies 40 allow for interchangeability of patterns created by the food punch assembly 10 in the food sheet. For example, a first removable punch having a first design, such as a square, and a first removable die having a complimentary design to the first removable punch may be removed from the food punch assembly, and replaced with a second removable punch having a second design, such as a circle, and a second removable die having a complimentary design to the second removable punch may be placed in the food punch assembly.

[0040] To use the food punch assembly 10, a die 40 is placed into the die receiving opening 20 of the base 14 and a punch 50 is placed into the punch receiving opening 30 of the lid 16. The food sheet is placed onto the food receiving surface 24 with the lid 16 in an open position. The lid 16 is then closed. A force is applied to the generally flat top surface 52 of the punch 50, causing the actuatable punch receiving surface 38 to move from the first position to the second position. The movement of the movable punch receiving surface 38 causes the punching protrusion 56 of the punch 50 to pass through the food sheet and into the opening 46 of the die 40. The lid 16 may then be reopened and the stamped food sheet removed. When the stamping of the food sheet is complete, the die 40 and the punch 50 may be removed from the punch base assembly 12. This allows the die 40 and the punch 50 to be more readily cleaned. Further, if a different stamping design is desired, a second punch 50 and a second die 40 with alternate designs from the first punch 50 and the first die 40 may be inserted into the punch base assembly 12.

[0041] FIG. 4 shows an edge punch assembly 100. The edge punch assembly 100 is similar to the punch assembly 10, except that the edge punch assembly 100 is adapted to provide a decorative effect to an edge of the food sheet, rather than cut a design from the food sheet. The edge punch assembly 100 comprises a punch base assembly 112 having a base 114 and a lid 116. The lid 116 hingedly connects to the base 114 via a hinge 118.

[0042] The base 114 is adapted to receive an edge die 140, while the lid 116 is adapted to receive an edge punch 150. The edge die 140 and the edge punch 150 are secured to the punch base assembly 112 in a generally identical manner to how the die 40 and the punch 50 are secured to the punch base assembly 12.

[0043] The punch base assembly 112, the base 114, the lid 116, and the hinge 118 operate similarly to the corresponding components of the punch assembly 10. Similarly, the operation of the edge punch assembly 100 is similar to the punch assembly 10, except the food sheet is positioned so that an edge of the food sheet is disposed between the edge die 140 and the edge punch 150.

[0044] Turning now to FIG. 5, an alternative embodiment of a food punch assembly 200 is shown. The food punch assembly 200 comprises a punch base assembly 212 having a base 214 and a lid 216. The food punch assembly 200 is similar to the punch assembly 10 described above, however the lid 216 has at least one aligning post 218 while the base 214 has at least one aligning receptacle 220 adapted to receive the aligning post 218 of the lid 216. The aligning post 218 and the aligning receptacle 220 assist in obtaining proper alignment of the lid 216 and the base 214 during the use of the food punch assembly 200. A backstop 222 is also provided on the base 214. The backstop 222 helps to align the food sheet being utilized with the food punch assembly 200, and prevents the food sheet from being inserted too far into the food punch assembly 200.

[0045] FIGs. 6-8 depict a die 240 a punch 250 and a punch storage cover 260 adapted to be used with the food punch assembly 10, 200. The die 240 is similar to the die 40 described above, but the die 240 comprises a chamfer 242. The chamfer 242 helps to align a punching protrusion 256 of the punch 250 into the die 240 during use.

[0046] The punch 250 is similar to the punch 50 described above, but the punch 250 has a bridging section 252. The bridging section 252 adds structural rigidity to the punch 250. The bridging section 252 is disposed a distance from a distal end of the punching protrusion 256 so as not to interfere with the stamping operations of the punch 250. The bridging section 252 helps to maintain a shape of the punching protrusion 256. As shown in FIG. 7, the punching protrusion 256 may not be a uniform length on the punch 250. Extending regions 258 may be provided at various locations about the punching protrusion 256 that will initially contact the food sheet, to limit the amount of force initially applied to the food sheet by the stamp 250. As shown in FIG. 7, a plane 259 formed through the extending regions 258 indicate the different lengths of portions of the punching protrusion 256.

[0047] FIG. 6 also shows a punch storage cover 260. The punch storage cover 260 forms a groove 262. The groove 262 has a complimentary shape to the punching protrusion 256 of the punch 250. The punch storage cover helps to protect the edge of the punching protrusion 256 while the punch 250 is not in use. Further, as shown in FIG. 8, the punch storage cover 260 may be used to hold the punch 250 in the die 240 when the punch 250 and die 240 are being stored. The punching protrusion 256 is placed through an opening in the die 240 and the groove 262 of the punch storage cover 260 receives the punching protrusion 256. Thus, the die 240 is secured between the punch 250 and the punch storage cover 260, allowing storage of the punch 250 and the die 240 as an assembly. [0048] FIGs. 9 and 10 depict an alternative embodiment of an edge die 340, an edge punch 350, and a punch storage cover 360 for an edge punch assembly 100 as described above. The edge punch 350 has at least one bridging element 352 to add structural rigidity to the edge punch 350. Further, the edge punch 350 has a punching protrusion 356 with a chamfer 354. The chamfer 354 helps to align the punching protrusion 356 with the edge die 340.

[0049] The edge die 340 has at least one reinforcing rib 342. The reinforcing rib 342 is adapted to increase the structural strength of the die 340, and limit flexing and deformation of the die 340 during use.

[0050] Similar to the punch storage cover 260, the punch storage cover 360 is adapted to cover the punching protrusion 356 of the edge punch 350. The punch storage cover 360 may be used to hold the edge punch 350 in the edge die 340 when the edge punch 350 and the edge die 340 are being stored. The punching protrusion 356 is placed through an opening in the edge die 340 and the punch storage cover 360 receives the punching protrusion 356. Thus, the edge die 340 is secured between the edge punch 350 and the punch storage cover 360, allowing storage of the edge punch 350 and the edge die 340 as an assembly.

[0051] It is contemplated that the embodiments described above may be made from injection molded polymeric materials with exacting tolerances. For instance, a clearance between a punch and a die may not exceed 0.005 inch to function as intended.

[0052] While specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying Claims.