TECHNICAL FIELD The present invention relates to a toaster. More particularly, the invention relates to a toaster that can also be used for applying foodstuff to a toasted bread slice.

BACKGROUND

Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge. It is well appreciated by householders that the application of foodstuff such as butter to bread, after the toasting can be inconvenient and time consuming. For example, in many instances foodstuff like butter may be too solid and needs to be melted before the foodstuff is ready to be spread on a slice of bread that has been toasted.

Therefore, there is a need to provide a toaster that can simultaneously toast a slice of bread and assist with the application of foodstuff in order to coat or spread the foodstuff on toasted bread in a fast and efficient manner. SUMMARY OF THE INVENTION

In a first aspect, the invention provides a bread toaster for toasting a bread slice, the toaster comprising: a toaster frame which defines a bread receiving slot for receiving the bread slice; a heating device arranged in the toaster frame for toasting the bread slice when the bread slice is received into the toaster frame; an applicator unit positioned relative to the toaster frame for applying one or more food materials on a toasted bread slice toasted by the heating device, the applicator unit comprising one or more receptacles adapted for receiving packaged food material, the food receiving receptacles

Substitute Sheet

(Rule 26) RO/AU extending generally in a transverse direction relative to the plane of the bread slice received in the toaster frame.

In an embodiment, the applicator unit comprises one or more food releasing means for releasing the packaged food material, the releasing means comprising a pressure application device and/or an additional heating device for releasing the packaged food material. Preferably, the pressure application device is adapted for applying a force along packaging walls of the packaged food material and thereby releasing the food material through one or more openings provided in the package containing the food material. The additional heating device may be adapted for heating the packaged food material.

In one embodiment, the pressure application device is an extruder ram. In some embodiments the extruder ram is controlled by an actuator which provides pulsed power to the ram which may be electrically, hydraulically or pneumatically motivated.

In an embodiment, the toaster frame comprises a positioning arrangement for positioning the bread slice in a substantially flat orientation. Preferably, the positioning arrangement comprises positioning the bread slice in a substantially flat orientation on a bread receiving surface.

The positioning arrangement may comprise a conveying means; preferably a downwardly directed conveying means, for conveying one or more bread slices, received into the bread receiving slot, to the bread receiving surface, preferably a bread receiving tray.

In an alternative embodiment, the positioning arrangement may allow relative movement of the applicator unit relative to the bread receiving surface to allow the food material to be coated across a surface of the toasted bread during use.

In an embodiment, the bread toaster further comprises a lid adapted for being releasably opened for either inserting packaged food material into the food

Substitute Sheet

(Rule 26) RO/AU receiving receptacle or removing the packaged food material out of the food receiving receptacle. Preferably, the lid is adapted for engaging with walls of the package containing the packaged food material. Preferably, the receptacle positions the packaged food material in a transverse orientation relative to the plane of the toasted bread, positioned in a substantially flat orientation, for applying the food material on the toasted bread. In an embodiment, the bread toaster further comprises indicia for indicating progress of toasting of the bread, during use.

In especially preferred embodiments the package containing the packaged food material has at least one aperture upon its surface for evenly discharging the packaged food stuff contained therein.

In other preferred embodiments, the applicator unit includes an extrusion separator. Preferably, the extrusion separator is any of a wire, filament or blade for removing excess food stuffs from the or each aperture of the package after the food material has been dispensed.

In an embodiment, the bread toaster further comprises an outlet slot for allowing passage of the toasted bread therethrough wherein preferably the outlet slot is arranged relative to the applicator unit for allowing food material to be coated on the toasted bread before positioning the coated and toasted bread in the outlet slot. Preferably, the toaster further comprises an outwardly extending tray positioned at the outlet slot for positioning the toasted bread.

In an embodiment, the toaster further includes one or more controllers for controlling a quantity of food material coated on the toasted bread during use.

In an embodiment, the controllers include an optical sensor for measuring the length of a bread slice being toasted.

Substitute Sheet

(Rule 26) RO/AU BRIEF DESCRIPTION OF THE DRAWINGS

Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows: Figure 1 is a first perspective view of a toaster 100 in accordance with a first embodiment of the present invention.

Figure 2 is a second perspective view of the toaster 100 in accordance with the first embodiment of the present invention.

Figure 3 is a first top-down perspective view of the toaster 100 in accordance with the first embodiment of the present invention in a first operating configuration. Figure 4 is a second top-down perspective view of the toaster 100 in accordance with the first embodiment of the present invention in a second operating configuration.

Figure 5 is a first perspective view of a toaster 200 in accordance with a second embodiment of the present invention.

Figure 6 is a second perspective view of a toaster 200 in accordance with the second embodiment of the present invention. Figure 7 is a third perspective view of a toaster 200 in accordance with the second embodiment of the present invention.

Figure 8 is an end view of a toaster 200 in accordance with the second embodiment of the present invention.

Substitute Sheet

(Rule 26) RO/AU Figure 9 is a first perspective view of a toaster 300 in accordance with a third embodiment of the present invention. Figure 10 is a second perspective view of the toaster 300 in accordance with the third embodiment of the present invention.

Figure 11 is a first sectional view of the toaster 300 in accordance with the third embodiment of the present invention.

Figure 12 is a second sectional view of the toaster 300 in accordance with the third embodiment of the present invention.

Figures 13a through 13k is a series of section, front, side, top, bottom and perspective views of the food pods P1 and P2. Figure 13a is a top view. Figures 13i, 13j and 13k are bottom views of variations of the food pods.

Figures 14a and 14b are perspective views of an extruder ram 410 in closed and open position respectively.

Figure 15 is a perspective view of heating elements 401 suitable for the purposes of the present invention.

Figure 16 is perspective view of the conveyor 136.

Figures 17a, 17b and 17c is a series of views of the extruder separator 420.

Figures 18a, 18b and 18c is a series of views indicating the operation of the optical sensor.

Figure 19 is a view of some of the assembled internal components of an embodiment of the toaster 100 or 200.

Substitute Sheet

(Rule 26) RO/AU Figures 20 through 24 indicate the progress of a slice of toast through and operation of the internal components of the toaster 100 or 200.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to Figures 1 to 4, a first embodiment of a toaster 100 is illustrated. The toaster 100 comprises a toaster frame 120 which defines a downwardly directed bread receiving slot 110 for receiving the bread slice. The downwardly directed slot 110 allows a slice of bread to be inserted therein. The downward directed orientation of the slot 1 10 allows the slice of bread to be conveyed and positioned for being toasted by a heating device in the form of heating elements 401 arranged in the toaster frame 120 for evenly toasting each side of the bread. The toasting may be controlled or initiated by way of controlling means 129 provided on an outer wall of the toaster frame 120. The heating elements 401 can be exposed wire, glass tubes or any suitable heat source. The toaster frame 120 also includes indicating means in the form of a circular progress indicator 127 for indicating progress of toasting of bread during use. LED lights or other alternative lighting means may be provided for the progress indicator 127. Alternatively, progress indicator 127 may also control the extent of toasting.

The toaster frame 120 or base assembly 220 can also house a conveyor 136 oriented substantially horizontally for progressing the bread through the toaster 100 at a speed determined by the user. The horizontally oriented conveyor 136 can move backward and forward if bread is loaded from the front end of the toaster 100 or 200, or always forward if bread is loaded from the rear, particularly for continuous processing. The conveyor 136 can be similar to that illustrated in Figure 16 and may have parallel belts 137 and 138 with wire spanning the belts, a 'walking' mechanism of two interleaved grids, a wire chain or a reciprocating sled.

The toaster frame 120 also includes a food applicator unit 150 positioned for applying one or more food materials on a toasted bread slice that has been toasted by the heating device. The applicator unit 150 comprises two

Substitute Sheet

(Rule 26) RO/AU elongate receptacles 152 and 154 adapted for receiving packaged food pods P1 and P2 respectively. The food receiving receptacles 152 and 154 extend generally in a transverse direction relative to the plane of the bread slice received in the bread receiving slot 110. The orientation of the food receiving receptacles 152 and 154 in a transverse orientation relative to the received bread slice allows the food pods P1 and P2 to be suitably positioned in a food dispensing position and conveniently release foodstuff from one or both pods P1 and P2 and apply the released foodstuff on a toasted bread slice. During use, a user may release a hinged lid 125 by using a handle 128 for releasing the locking mechanism 123 and opening the lid 125 (shown in Figure 4) for either inserting pods P1 and P2 into the food receiving receptacles 152 and 154 respectively or removing the pods P1 and P2 out of the food receiving receptacles 152 and 154. The toaster frame may incorporate an LED indicator light 126 for indicating to the user whether the applicator unit may be opened (for example blue light) or is locked and in use (for example, red light).

Preferably the bottom of each of the pods P1 and P2 is sealed and provided with a self-opening arrangement. By way of example, the applicator unit 150 may apply a pressure upon the walls of the pods P1 and P2 by way of a mechanical pressure application means. A "duck-bill" valve may be provided at an end portion of each of the pods P1 and P2 to optionally open the valve upon application of pressure on the walls of the pods P1 and P2 in order to release packaged foodstuff from the pods P1 and P2 and apply the foodstuff on a toasted bread slice. Once the foodstuff released from the pods P1 and P2 has been uniformly applied across the surface of the toasted bread (B1; as shown in Figure 1 ), the toasted bread slice is positioned in an outlet slot 130 and supported on a slidable bread supporting tray 135.

Figures 13a through 13k provide a number of views of the pods P1 or P2. The bottom surface of the pods P1 and P2 can incorporate a single aperture or a multiplicity of apertures 402 for evenly discharging the packaged food stuff contained therein onto toasted bread. The apertures can be of any size and shape according to the user's requirements, for example, for aesthetically

Substitute Sheet

(Rule 26) RO/AU discharging the food stuff onto the toasted bread or to facilitate the even and rapid discharge of packaged food stuffs contained within the pods P1 and P2.

In some embodiments receptacles 152 and 154 may include a drilled extrusion plate or rubber membrane which includes drilled apertures corresponding to those on the bottom surface of the pods P1 and P2.

In some embodiments of the invention the lid 125 may house a suitable food releasing means such as an extruder ram 410 as indicated in Figures 14a and 14b. The extruder ram 410 exerts sufficient force on the food pods P1 and P2 when they are placed within the applicator unit 150 and the lid 125 is closed to extrude the packaged food stuffs through the apertures 402 located on the or each pod's bottom surface. The extruder ram 410 can be electrically, hydraulically or pneumatically motivated. An electrically motivated extruder ram 410 may have its current supplied in short bursts of tenths of seconds so as to control the ram speed while maintaining full force upon the pods P1 and P2. The linear actuator used to drive the extrusion ram 410 can be, for example, a DC motor driven geared screw although those skilled in the art will recognise that other forms of actuation might equally be used. Most DC motors used in high torque tools are controlled by pulse wave modulation which allows full voltage to be delivered to the motor in micro-second pulses. It was found however that the ram 410 had stiction (resistance to initial movement) which would cause the ram 410 to stall or extrude too much once stiction was overcome. The use of relatively long (10ths of seconds) pulses of power overcomes the problem of stiction and permits a controlled flow from the apertures 402. The power pulses can be controlled with a potentiometer and the setting displayed on an LCD display.

The toaster 100 incorporates the automatic application of viscous foods (typically spreadable foods such as butter, vegemite, jam, etc.) to bread following the toasting process. The use of the toaster 100 results in significant time savings in toasted food preparation and also potential reduction of food wastage through machine controlled spreading of these viscous foods. Another advantage provided by the toaster 100 is that the toaster reduces the

Substitute Sheet

(Rule 26) RO/AU need for human input or human intervention that would otherwise be needed for applying foodstuff to toasted bread. Another advantage is that the food material can be spread evenly on the toasted bread slice.

Figures 5 to 8 illustrate a second embodiment of a toaster 200. Like reference numerals indicate features which have been described in previous sections. The toaster 200 comprises a bread supporting base assembly 220 that supports and toasts one or more slices of bread positioned thereon. The base assembly 220 may be provided with heating elements for toasting one or more slices of bread positioned on the base assembly 220. Alternatively, heating elements 401 may also be provided on a movable frame 235 positioned upon the base assembly 220. The movable frame 235 is provided with a mounting arrangement for mounting a food applicator unit 230. The food applicator unit 235 is positioned in a spaced relationship relative to the base assembly 220 to define a bread receiving slot 210 that allows a sliced of bread to be positioned in the space in between the food applicator unit 230 and the base assembly 220 during use. A slidable controller 225 can be incorporated into the base assembly 220 to regulate the extent of toasting. The applicator unit 230 comprises an elongate receptacle for receiving a packaged food pod P. The food receiving receptacle extends generally in a transverse direction relative to the plane of the bread slice positioned on the base assembly 220. The orientation of the food receiving receptacle in a transverse orientation relative to the bread slice positioned in the space in between the applicator unit 230 and the base assembly 220 allows the food pod P to be suitably positioned in a food dispensing position and conveniently release foodstuff from the pod P and apply the released foodstuff on the toasted bread slice. During use, a user may release the hinged lid 125 for either inserting the pod P into the food receiving receptacles or removing the pod out of the food receiving receptacle in the applicator unit 230. Advantageously, a pair of lids 125 may be provided on either side of the applicator unit 230 for positioning two food containing pods P in parallel. The or each lid may incorporate an LED indicator light 126 for indicating to the

Substitute Sheet

(Rule 26) RO/AU user whether the applicator unit 230 may be opened (for example blue light) or is locked and in use (for example, red light).

A heating element 401 in combination with a pod heating and discharge mechanism are conveniently located within a housing of the applicator unit 230 that sits in a perpendicular orientation relative to the horizontal base assembly 220 and slidably engages with the base assembly 220. During use, the frame 235 with the mounted applicator unit 230, by way of a pair of housing support arms which can be slidably removed from the housing of the applicator unit 230 for cleaning. The housing moves along a pair of longitudinal channels located along the base assembly 220. In one operational configuration, as the applicator unit 230 moves along the plane of the base assembly 220, the applicator unit 230 also applies heat and toasts the sliced bread placed upon the base assembly 220 and discharges the foodstuff of the pod P onto the toasted bread. The simultaneous toasting and application of foodstuff may be achieved by way of a single sweep or by way of two sweeps (ie first to toast the bread slice and then to spread).

The discharge mechanism of the applicator unit 230 can include an extruder ram 410 as shown in Figures 14a and 14b and described above.

Referring to Figures 9 to 12 a third embodiment of the toaster 300 is illustrated. The toaster 300 comprises a toaster frame 320 which includes a bread receiving chute that includes downwardly directed bread receiving slots 310 for receiving the bread slice. The downwardly directed slots 310 allow two slices of bread to be inserted therein. The downward directed orientation of the slots 310 allows an inserted slice of bread to be conveyed onto a first receiving plate 312 that assists in further conveying and positioning the bread onto a toasting plate 314. Advantageously, the toasting plate 314 may include heating elements arranged for toasting a slice bread positioned upon the toasting plate 314. The toasting plate 314 also includes a pivoting mechanism for pivoting the toasting plate 314 in between a flat configuration (toasting position shown in Figure 11 ) and a tilted (non-toasting position shown in Figure 12). The extent of toasting may be controlled by way of a slidable

Substitute Sheet

(Rule 26) RO/AU controller 315 located upon the toaster frame 320. Additional controllers 325 provided on an outer wall of the toaster frame 320 can control other functions of the toaster 200 such as defrosting, start, stop, 1 pod, 2 pods, according to the user's requirements.

The toaster frame 320 also includes a food applicator unit 350 positioned for applying one or more food materials on a toasted bread slice positioned on the toasting plate 314. The toaster frame 320 comprises two elongate receptacles 352 and 354 adapted for receiving packaged food pods P1 and P2 respectively. The food receiving receptacles 352 and 354 extend generally in a transverse direction relative to the plane of the bread slice received in the bread receiving slots 310. The food applicator unit 350 includes a pressing plate 355 which is adapted for pressing against the side walls of food pod P1 positioned on a pod receiving plate 357 for dispensing food stuff from the pod P1 onto a toasted surface of the bread slice. The food applicator unit 350 can also include an extruder ram 410 suitably adapted to provides the force necessary to operate pressing plate 355.

Upon being toasted, the toasting plate 314 is pivoted into a tilted position to convey the toasted and coated bread slice out through an outlet slot 330. A bread supporting tray 335 is provided for supporting the toasted and coated bread slice B as clearly shown in Figure 12.

The toasters 100, 200 or 300 in further improvements may incorporate a mechanism to adjust or move an inserted pod up and down to apply foodstuff. Alternatively, the toaster may alter the height of the toasted bread to meet the bottom of the pod. An advantage to the automatic application of viscous foods to toasted bread, is that the user(s) can program a custom amount of spread to apply to their toast, and rely on the toaster to replicate this each time by saving it as a 'setting'. An advantage of the first embodiment of the drilled extrusion plate is the even spreading of food material onto the toast. A further advantage of this additional functionality is that the toaster can be preprogrammed to control the quantity of foodstuff dispensed on toasted bread.

Substitute Sheet

(Rule 26) RO/AU Alternatively, the amount of spread dispensed can be automatically regulated by an optical sensor 430, comprised of a laser and an optical resistor, which reads the length of the bread to which spread is to be applied. The optical sensor 430 is. Figures 18a, 18b and 18c show optical sensor 430 which produces a beam of light which is interrupted as a slice of bread moves at a known velocity. The time and length of beam interruption is used to determine the length of and position of the slice, permitting metering of the extrusion of spread according to the dimensions of the slice of bread. In embodiments with more than one extruder ram 410 the additional ram is controlled with a delay to compensate for the difference in position of the toast as it moves forward along the conveyor 136.

The pods for holding or containing the packaged foodstuff may be improved or modified in many different ways. For example, food containing pods may include a flat lid section that may be compressed by the lid 125 when the lid is shut in order dispense foodstuff out from a bottom portion of the pod. If pods having soft and flexible outer walls are used, the method for releasing and applying the viscous foods to the toast would be through sideways pressure applied by the engaging mechanism provided in the toaster. It is also desirable that the toaster including the associated mechanisms and parts do not make contact with any foodstuff contained in the pods. Such an arrangement may allow the pods to be removed and discarded without need for cleaning the device. An extrusion separator 420, as illustrated in Figure 17, can be included within the toaster frame 120 or base assembly 220 or adapted for use within toaster 300. Extrusion separator 420 consists of a wire, filament or blade that moves across the multiplicity of apertures 402 located on the bottom surface of the pods P1 and P2 or alternatively, the drilled extrusion plate apertures if included, to remove excess food stuffs from the apertures after the extruder ram 410 has stopped moving. The extrusion separator 420 can be actuated by any of a motor, servo or linear actuator or can be attached directly to conveyor 136 according to the user's requirements.

Substitute Sheet

(Rule 26) RO/AU The toaster may also be designed to preferably enable customisation of the volume of food to apply to the toast. In such a scenario it would also be preferable if food is stored in re-usable pods as opposed to single use containers in order to avoid wastage. The toaster may be adapted for allowing application of more than one type of foodstuff by providing for two pods to be positioned for allowing the two pods to dispense foodstuff simultaneously on the toasted bread. The toaster may also be adapted for detecting if the pods are empty and provide notifications to the user to notify them if the pods need to be replaced.

In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term "comprises" and its variations, such as "comprising" and "comprised of is used throughout in an inclusive sense and not to the exclusion of any additional features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Throughout the specification and claims (if present), unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms.

Any embodiment of the invention is meant to be illustrative only and is not meant to be limiting to the invention. Therefore, it should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention.

Substitute Sheet

(Rule 26) RO/AU