MXPA06000082A - Method for use in baking articles of manufacture and mold for use in said method - Google Patents

Abstract

The present invention relates to a method for producing baked goods and a mold apparatus having a cavity in a desired shape for use in said method, the mold apparatus comprising a gap that allows for venting of vapor produced during heating or baking of a mixture in the mold apparatus but does not allow any significant amount of the mixture to escape from the cavity of the mold apparatus via the gaps.

Description

For two-letter codes and other abbreviations, refer to the "Guidance Notes on Codes and Abbreviations" appearing at the beginning-ning ofeach regular issue of the PCT Gazette.

METHOD FOR USE IN ARTICLES OF MANUFACTURE OF BAKING AND MOLD FOR USE IN SUCH METHOD FIELD OF THE INVENTION The invention relates in general to methods for the production of baked goods and articles of manufacture and molds for use in such methods.

BACKGROUND OF THE INVENTION Most molding systems that produce baked goods nowadays comprise a two-piece mold with a female lower half and a male upper half. In some cases, the lower female half is made up of two halves - for example, a female ice cream cone mold is usually made up of two halves as can be seen in the US patent. No. 5,693,355 to Haas. Typically the molds are heated and remain hot at a temperature that is sufficient to bake the material deposited in the molds within a certain period without burning the material. As the product is baked, the water or other liquid in the mixture is converted to steam or other vapor that must be discharged from the mold to allow proper formation of the final product. Typically this is achieved by means of vents in the mold apparatus. As an unexpected result of having vents for vapor or steam to escape, the surplus material is also typically ejected from the mold cavity by the vent. The venting of excess material causes a significant waste of both raw materials and energy. The loss of raw materials, an important cost in the manufacturing process, can be higher than 20% to 30%. Similarly, to compensate for the loss of material, additional material must be added to the mold which requires additional energy for baking, which is also a significant expense in most processes. In addition, additional steps must be added to the manufacturing process for the removal of the remaining material from the baked product to produce the final product. The vents are usually roughened and / or sanded and then discarded together with the remaining material. Furthermore, the roughing process itself can cause defects and thus increase the probability of rejection of the final product. Finally, if ventilation wear occurs, the entire mold can be replaced or material must be added to the mold because the cross section of the vent is an important component that controls how much material will be expelled by the ventilation of the mold apparatus. Accordingly, there is a need in the art for improved molds and methods for using such molds for the manufacture of baked goods that allow the venting of steam produced during heating or baking without substantial loss of material.

BRIEF DESCRIPTION OF THE INVENTION It is an object of the present invention to provide a method for manufacturing baked goods or goods that allows the venting of steam produced during heating or baking without a substantial loss of material. It is another object of the present invention to provide a mold having a gap or gaps for venting the vapor produced during heating or baking without substantial loss of a material. These and other aspects of the present invention that may be apparent to those skilled in the art through the following description of the invention are achieved by a method for baking articles of manufacture and a mold for use in said method. One embodiment of the present invention is a method comprising the steps of adding a mixture to a mold apparatus having a cavity and baking the mixture in the mold apparatus until the mixture has a stable shape, wherein upon contacting the mixing with the surface of the cavity, a skin forms on the outside of the mixture and wherein the mold apparatus comprises a gap such that steam can exit through the cavity of the mold apparatus through the gap without substantial loss of the mixture through the gap. Another embodiment of the present invention is a mold apparatus comprising a cavity, a gap in communication with the cavity and the exterior of the mold apparatus for ventilating steam wherein the gap is configured in such a manner as to allow steam to escape from the cavity and simultaneously not allow a mixture to escape from the cavity. A third embodiment of the present invention is a mold apparatus comprising a male mold half, a female mold half wherein the contact of the male mold half and the female mold half forms a cavity in a desired shape, and a gap in communication with the cavity and the exterior of the mold apparatus for ventilating steam wherein the gap is configured in such a way as to allow steam to escape from the cavity and simultaneously not allow a mixture to escape from the cavity.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a cross-sectional view of an open two-piece mold. Figure 2 is a cross-sectional view of a closed two-piece mold. Figure 3 shows a vent in a mold. Figure 4 is a perspective view of a venting feature applied horizontally to a female mold.

Figure 5 is a cross-sectional view of a venting feature applied in a horizontal manner to a female mold. Figure 6 is an exploded perspective view of a venting feature applied horizontally to a female mold. Figure 7 is a perspective view of a venting feature applied vertically to a female mold. Figure 8 is a cross-sectional view of a venting feature applied vertically to a female mold. Figure 9 is an exploded perspective view of a venting feature applied vertically to a female mold. Figure 10 is a perspective view of a venting feature applied horizontally to a male mold. Figure 11 is a cross-sectional view of a venting feature applied horizontally to a male mold. Figure 12 is an exploded perspective view of a venting feature applied horizontally to a male mold. Figure 13 is a perspective view of a venting feature applied vertically to a male mold. Figure 14 is a cross-sectional view of a venting feature applied vertically to a male mold. Figure 15 is an exploded perspective view of a venting feature applied vertically to a male mold.

DETAILED DESCRIPTION OF THE INVENTION In order to fully understand the manner in which the details mentioned above and other advantages and objects according to the invention are achieved, a more detailed description of the invention will be presented by reference to specific embodiments thereof. 1. - Molding method A method according to the present invention comprises the steps of providing a mold apparatus having a cavity in the form of a desired end product and a gap or gaps for venting the steam of the mold apparatus produced during heating or baking, heating or baking the mold apparatus, adding a mixture that is liquid or semi-liquid to the cavity of the mold apparatus prior to closing the mold apparatus and closing the mold apparatus, wherein as vapor or steam is produced in the cavity during heating or baking, the mixture is pushed by vapor pressure or steam to completely fill the cavity, and once sufficient contact of the mixture with the heated mold apparatus is achieved a skin forms on the outer surface of the mold. mixture, and the skin is permeable or semipermeable to steam and the skin and gap are such that, in combination, allow the escape of steam or steam from the cavity to the outside of the apparatus of mold but do not allow any significant amount of the mixture to escape. Any significant amount of mixture as referred to herein is any amount whose loss can cause any of the above disadvantages found in the prior art in a significant amount, such as waste of raw materials, wasted energy needed to heat the additional mixture, additional processes to eliminate the excess material to form the final product and obstruct the gap or gaps. The vapor escapes while the mixture remains in the cavity because the gap is of sufficient size - that is, small enough - that the skin formed on the surface of the mixture from the contact of the mixture with the heated mold surface, when under sufficient pressure of steam or steam produced during the heating or baking of the mixture, allows steam or steam to escape through the skin and then through the gap to the outside of the mold apparatus without breaking the skin. Since the skin is not permeable to the mixture, which may still be liquid or semi-liquid prior to the completion of heating or baking, the mixture can not escape from the cavity of the mold apparatus. The above method according to the present invention allows the venting of the vapors produced during baking without a significant loss of mixture and the associated disadvantages of said loss outlined above such as raw material waste, waste of energy needed to heat additional mixture, additional processes to eliminate the excess material to form the final product and the obstruction of the gap or gaps.

The aforementioned method according to the present invention can be used to manufacture both baked goods and other baked goods as starch-based materials for use as food containers and the like. Typically the mixtures for use in said method are based on water. However, one skilled in the art recognizes that mixtures do not need water base, as mixtures based on alcohol or other mixtures not based on water. Specific examples of mixtures that can be used in such methods should be readily apparent to one skilled in the art and include, without restriction, common baking mixtures such as waffle, cookie dough or ice cream cone shake, starch based mixtures comprising starch and water and mixtures comprising composite materials mixed with resins that form skins that remain permeable to the gases produced during heating or baking. In addition, specific baking procedures such as heating temperature and time will vary depending on the specific mixture to be heated or baked and should be apparent to one skilled in the art. 2. - Mold apparatus With reference to figures 1 and 2 a mold 5 according to the present invention having a male mold half is shown and one female mold half 15 to form a cavity 20. The mold 5 can have a variety of shapes depending on the desired shape of the final product to be baked. The mold 5 shown is configured in such a way that the cavity 20 has the shape of a bowl. The male mold half 10 and the female mold half 15 can be held together by means commonly known in the art such as hydraulic press, mechanical locking mechanism or clamp mechanism, which are not shown. As described above, the complete filling of the cavity 20 with a mixture that is initially liquid or semi-liquid is driven by the force created during heating or baking by the formation of steam in the cavity 20. The steam pressure then pushes the mixture to substantially fill the cavity 20. Consequently, it is not necessary to press the male and female mold halves 10 and 15 together to push the material to fill the cavity 20 as long as the male and female mold halves 10 and 15 remain in one position during heating or baking. However, both mechanical and vapor pressure could be used in combination to fill the cavity 20 if desired. Referring to Figure 3, a section of the mold 5 is shown with a gap 25 for venting steam or other vapor formed during heating or baking from the cavity 20 to the exterior of the mold 5. The gap 25 has a first portion 30 in communication with the cavity 20 and a second portion 35 in communication with the first portion 30 and the exterior of the mold 5, wherein the second portion 35 is wider than the first portion 30. The gap 25 is configured in such a way that, in combination with the skin formed during heating or baking as described above, the gap 25 allows the venting of steam or other vapor formed during heating or baking without allowing the mixture to escape. The dimensions of gap 25 will vary depending on the particular mixture used. In general, it has been found that the first portion 30 of the gap 25 has a width preferably of about 0.0025 cm. to about 0.07 cm., and more preferably about 0.0025 cm. at about 0.038 cm., and more preferably about 0.0025 cm. to about 0.015 cm, and has a length preferably of about 0.0025 cm. at about 5.08 cm., and more preferably about 0.0025 cm. to about 1.27 cm., and more preferably about 0.0025 cm. to about 0.25 cm. In addition, the first portion 30 or the second portion 35 of the gap 25 may vary or may be constant along its corresponding length. The material used to form the mold 5 can be selected from common materials known in the art including, without restriction, metals such as cast iron and aluminum or other suitable materials. Furthermore, depending on the specific material to be cted and the specific mixture to be formed by the above method, the surfaces of the cavity 20 of the mold 5 can be treated with methods such as sand blasting, galvanizing with metals such as nickel plating or other methods of treatment commonly known in the art, wherein said surface treatment may assist in the formation of desired characteristics on the surface of the final product or improve the production process such as facilitating the removal of the product from the cavity 20 of the mold 5 after the training. In addition, a heating mechanism can be incorporated in the mold 5. Additionally, with reference to Figure 2, during molding the mold 5 can remain slightly open leaving a space with the 37 at the outermost interface between the male mold half 10 and the female mold half 15 extending around the circumference of the outermost interface so that steam can initially escape through said space with the 37. As the heating or baking process proceeds, the mold 40 closes substantially sealing the space with the 37. This substantial closure of the mold 40 will ensure that the male mold half 10 and the female mold half 15 are substantially aligned prior to the product becoming stable and will also allow some heat transfer between the half of male mold 10 and female mold half 15 to reduce the temperature differences between the male mold half 10 and the female mold half 15. to. Vent Configurations Referring to Figures 4 to 6, a mold 40 according to the present invention having a female mold half is shown 45 and a male mold half 50 with horizontal vent of the female mold half 45. Referring to Figure 4, the female mold half 45 is shown with a gap 55 for venting the gas formed during heating or baking. Referring to Figure 6, the female mold half 45 further comprises a lower half 60 and an upper half 65 held together by fasteners 90 as bolts or screws. Referring to Figure 5, a cross section along the plane AA of Figure 4 is shown where the gap 55 is visible on opposite sides of the female mold half 45, the gap 55 has a channel 85, a first portion 70 and a second portion 75, wherein the second portion 75 is wider than the first portion 70. Section B of Figure 5 increases a portion of the mold 40 that shows a cavity 80 and the first portion 70, the second portion 75 and the channels 85 of the gap 55. Referring to Figure 6, there is shown an exploded view of the mold 40 having the gap 55 in the female mold half 45 wherein the female mold half 45 has an upper half 65 and a lower half 60 wherein the lower half 60 of the female mold half 45 has channels 85 which, when the lower half 60 and the upper half 65 of the female mold half 45 are assembled and assembled together by fasteners 90 , they form the gap 55 as shown in Figures 4 and 5. Additionally, when assembled, the first portion 70 and the second portion 75 of the gap 55 are in communication with the full circumference of the mold cavity 80 wherein the upper half 65 and the lower half 60 of the female mold half 45 are joined, and additionally they are in communication with the channels 85 which in turn are in communication with the outside of the mold 40.

Referring to Figures 7 to 9, there is shown a mold 100 in accordance with the present invention having a male mold half 105 and a female mold half 110 having vertical vent in the female mold half 110. Half of female mold 110 further comprises a first half 115 and a second half 120 held together by fasteners 125 and having a gap 130 for venting steam or steam during heating or baking, the gap 130 formed by notches in at least one of the first half 115 or the second half 120 of the female mold half 110. Referring now to Figure 8, a cross section is shown along the plane CC of Figure 7 where the gap 130 is visible in the middle of female mold 110. Section D of Figure 8 increases a portion of the mold 100 that shows the cavity 135 and the first portion 140 and the second portion 145 of the gap 130, wherein the second portion 145 is wider than the first portion. porc ion 140 and wherein the cavity 135 is in communication with the first portion 140 of the gap 130 which in turn is in communication with the second portion 145 of the gap 130 which in turn is in communication with the outside of the female mold half 110. Referring to Figure 9 there is shown an exploded view of the mold 100 wherein the first half 115 and the second half 120 of the female mold half 110, held together by fasteners 125, when assembled form the first portion 140 and second portion 145 of the gap 130 by contacting the first half 115 and the second half 120 of the female mold half 110 and wherein the first portion 140 and the second portion 145 of the gap 130 extend to along the entire length of the cavity 135 where the first half 115 and the second half 120 of the female mold half 110 coincide. Referring to Figures 10 to 12, a mold 160 according to the present invention is shown having a male mold half 165 and a female mold half 170 and having horizontal vent in the male mold half 165. Half male mold 165 has a gap 175 for venting steam during heating or baking. With reference to figure 11, a cross section is shown along the EE plane of Figure 10 where the vent gap 175 is visible in the male mold half 165. The section F of Figure 11 increases a portion of the mold 160 that shows a cavity of molding 180 and a first portion 185, a second portion 190 and a channel 95 of the gap 175, wherein the second portion 190 is wider than the first portion 185. Additionally, the molding cavity 180 is in communication with the first portion 185 of the gap 175 which in turn is in communication with the second portion 190 of the gap 175 which in turn is in communication with channel 195 of the gap 175 which in turn is in communication with the outside of the middle male mold 165. Referring to Figure 12 there is shown an exploded view of the mold 160 wherein the male mold half 165 further comprises a first half 205 and a second half 210 held together by fasteners 200 where, when or are assembled, the first portion 185 and the second portion 190 of the gap 175 is formed by contacting the first half 205 and the second half 210 of the male mold half 165 and wherein the first portion 185 and the second portion 190 of the gap 175 extend along the entire circumference of the cavity 180 where the first half 205 and the second half 210 of the male mold half 165 coincide. Referring to Figures 13 to 15, a mold 250 according to the present invention having a male mold half 255 and a female mold half 260 having vertical vent in the male mold half 255 is shown. male mold 255 further comprises a first half 265 and a second half 270 held together by fasteners 295, and gaps 275 for venting the steam during heating or baking. Referring to Fig. 14, a cross section is shown along the plane GG of Fig. 12 where the gap 275 is visible in the male mold half 255. The section H of Fig. 12 increases a portion of the mold 250 showing the cavity 280 and the first portion 285 and the second portion 290 of the gap 275, wherein the second portion 290 is substantially wider than the first portion 285 and wherein the second portion 290 extends to the outside of the middle male mold 255 for venting steam or other vapor produced during heating or baking.

Referring to Figure 15, an exploded view of the mold 250 is shown where, when assembled, the cavity 280 is in communication with the first portion 285 of the gap 275 which in turn is in communication with the second portion. 290 of the gap 275 which in turn is in communication with the outside of the male mold half 255 with the 300. The first half 265 and the second half 270 of the male mold half 255, held together by fasteners 295, when assembled they form the first portion 285 and the second portion 290 of the gap 275 by contacting the first half 265 and the second half 270 of the male mold half 255 and wherein the first portion 285 and the second portion 290 of the gap 275 extends along the entire length of cavity 280 where first half 265 and second half 270 of male mold half 255 coincide. Although the invention has been described with respect to specific embodiments and examples, it will be readily apparent to those skilled in the art that modifications and adaptations of the invention are possible without departing from the essence and scope of the invention. Accordingly, the scope of the present invention is limited only by the following claims.

Claims (38)

NOVELTY OF THE INVENTION CLAIMS

1. - A mold apparatus comprising: a cavity; and a gap in communication with the cavity and the exterior of the mold apparatus for venting steam wherein the gap is configured in such a manner as to allow steam to escape from the cavity and simultaneously not allow the escape of any significant amount of a mixture of The cavity.

2 - The mold apparatus according to claim 1, further characterized in that when the mixture is added to the mold apparatus, a skin is formed on the external surface of the mixture, and wherein the gap is one size in combination with the skin that is sufficient to allow the escape of steam from the cavity and simultaneously does not allow the escape of any significant amount of the mixture from the cavity.

3. The molding apparatus according to claim 1, further characterized in that when the mixture is added to the mold apparatus, the formation of vapor causes the mixture to substantially fill the cavity and form a skin on the outer surface of the mold. mixing, and wherein the gap is one size in combination with the skin which is sufficient to allow the escape of steam from the cavity and simultaneously does not allow the escape of any significant amount of the mixture from the cavity.

4. - The mold apparatus according to claim 3, further characterized in that the gap also comprises a first portion and a second portion wherein the second portion is wider than the first portion.

5. The mold apparatus according to claim 4, further characterized in that the first portion of the gap has a width that is on a scale of about 0.0025 cm to about 0.038 cm.

6. The mold apparatus according to claim 5, further characterized in that the first portion of the gap has a length that is on a scale of about 0.0025 cm to about 5.08 cm.

7. A mold apparatus comprising: a male mold half, a female mold half wherein the contact of the male mold half and the female mold half forms a cavity in a desired shape; and a gap in communication with the cavity and the external surface for venting steam wherein the gap is configured in such a manner as to allow steam to escape from the cavity and simultaneously not allow the escape of any significant amount of a mixture from the cavity.

8. The mold apparatus according to claim 7, further characterized in that when the mixture is added to the mold apparatus the formation of vapor causes the mixture to substantially fill the cavity and form a skin on the external surface of the mixture, and wherein the gap is of a size which, in combination with the skin, is sufficient to allow the escape of vapor from the cavity while at the same time not allowing the escape of any significant amount of the mixture from the cavity.

9. The mold apparatus according to claim 8, further characterized in that it also comprises a press for keeping the male mold half in contact with the female mold half.

10. The mold apparatus according to claim 8, further characterized in that it also comprises a fastener for maintaining the male mold half in contact with the female mold half.

11. The mold apparatus according to claim 8, further characterized in that the female mold further comprises a first half and a second half held together by a removable fastener and the gap.

12. The mold apparatus according to claim 11, further characterized in that the gap further comprises a first portion in communication with the cavity of a second portion in communication with the first portion and the exterior of the mold apparatus and wherein the second portion is wider than the first portion.

13. The mold apparatus according to claim 12, further characterized in that the first portion of the gap has a width on a scale of about 0.0025 cm to about 0.038 cm.

14. - The mold apparatus according to claim 13, further characterized in that the first portion of the gap has a length on a scale of about 0.0025 cm to about 5.08 cm.

15. The mold apparatus according to claim 12, further characterized in that the gap is along the horizontal axis of the mold apparatus.

16. The mold apparatus in accordance with the claim 15, further characterized in that the second portion of the gap is in communication with a channel which is in communication with the exterior of the mold apparatus.

17. The mold apparatus in accordance with the claim 16, further characterized in that the gap is formed by notches in at least one of the first half or second half when the first half and the second half are in contact.

18. The mold apparatus in accordance with the claim 12, further characterized in that the gap is along the vertical axis of the mold apparatus.

19. The mold apparatus in accordance with the claim 18, further characterized in that the first portion of the gap has a width on a scale of about 0.0025 cm to about 0.038 cm.

20. The mold apparatus in accordance with the claim 19, further characterized in that the first portion of the gap has a length on a scale of about 0.0025 cm to about 5.08 cm.

21. - The mold apparatus according to claim 18, further characterized in that the gap is formed by notches in at least one of the first half or second half when the first half and the second half are in contact.

22. The mold apparatus according to claim 8, further characterized in that the male mold further comprises a first half and a second half held together by a removable fastener and the gap.

23. The mold apparatus according to claim 22, further characterized in that the gap further comprises a first portion in communication with the cavity and a second portion in communication with the first portion and the exterior of the mold apparatus and wherein the second portion is wider than the first portion.

24. The mold apparatus according to claim 23, further characterized in that the gap is along the horizontal axis of the cavity.

25.- The mold apparatus in accordance with the claim 24, further characterized in that the first portion of the arrow has a width on a scale of about 0.0025 cm to about 0.038 cm.

26.- The mold apparatus in accordance with the claim 25, further characterized in that the first portion of the gap has a length on a scale of about 0.0025 cm to about 5.08 cm.

27. - The mold apparatus according to claim 24, further characterized in that the second portion of the gap is in communication with a channel that is in communication with the outside of the mold apparatus.

28.- The mold apparatus in accordance with the claim 27, further characterized in that the gap is formed by notches in at least one of the first half or second half when the first half and the second half are in contact.

29. The mold apparatus according to claim 23, further characterized in that the gap is along the vertical axis of the mold apparatus.

30.- The mold apparatus in accordance with the claim 29, further characterized in that the first portion of the gap has a width on a scale of about 0.0025 cm to about 0.038 cm.

31.- The mold apparatus in accordance with the claim 30, further characterized in that the first portion of the gap has a length on a scale of about 0.0025 cm to about 5.08 cm.

32. The mold apparatus according to claim 29, further characterized in that the gap is formed by notches in at least one of the first half or second half when the first half and the second half are in contact.

33.- A method comprising: adding a mixture to a mold apparatus having a cavity; and baking the mixture in the mold apparatus until the mixture has a stable form; wherein at the contact of the mixture with the surface of the cavity a skin forms on the external surface of the mixture; and wherein the mold apparatus comprises a gap such that vapor can exit the mold cavity through the gap without substantial loss of the mixture through the gap.

34. The method according to claim 33, further characterized in that the skin allows steam to escape from the mold cavity through the gap without essentially losing any of the mixture through the gap.

35. The method according to claim 33, further characterized in that it also comprises the step of heating the mold apparatus prior to the addition of the mixture.

36. The method according to claim 33, further characterized in that the pressure of the formation of steam during heating causes the mixture to substantially fill the cavity of the mold apparatus.

37. The method according to claim 33, further characterized in that, under the pressure produced by the formation of steam during heating, the skin is vapor permeable but is not permeable to mixing in the gap.

38. The method according to claim 33, further characterized in that the gap further comprises a first portion and a second portion wherein the second portion is wider than the first portion. 39.- The method according to claim 38, further characterized in that the first portion of the gap has a width that is on the scale of about 0.0025 cm to about 0.038 cm. The method according to claim 39, further characterized in that the first portion of the gap has a length that is on a scale of about 0.0025 cm to about 5.08 cm.