WO1997045020A1

WO1997045020A1 - Method and tool for multi-layer dough adhesion

Info

Publication number: WO1997045020A1
Application number: PCT/US1997/008435
Authority: WO
Inventors: Susan M. Hayes-Jacobson; James P. Michaels
Original assignee: Pillsbury Co
Current assignee: Pillsbury Co
Priority date: 1996-05-29
Filing date: 1997-05-16
Publication date: 1997-12-04
Anticipated expiration: 1998-11-29

Abstract

Tools and methods are provided for simultaneously cutting, crimping and docking a multi-layered seam of a dough product. A cutting, crimping and docking tool having a cutting blade (14), an adjacent recessed crimping surface (16) and a plurality of docking pins (18) extending away from the crimping surface (16) are described. The method includes placing two layers of dough on a preparation surface. Selected portions of the layers of dough are pressed against the preparation surface using a cutting, crimping and docking tool. The cutting blade (14) of the tool cuts through an outer portion of the first and second layers of dough defining the edge of the filled dough product. The crimping edge simultaneously crimps together an inner portion of the first and second layers of dough while the pins (18) perforate a plurality of holes between the first and the second layer of dough.

Description

METHOD AND TOOL FOR MULTI-LAYER DOUGH ADHESION BACKGROUND OF THE INVENTION

The present invention is generally directed to a tool and method for sealing the edges of a filled dough product. More specifically, the present invention relates to a tool and method for simultaneously cutting, crimping, and docking the seams of a filled dough product.

Filled dough products, such as food pockets, pies and pastries, are food products which have an outer dough casing surrounding a filling, such as meat, sauce, cheese or other foods. Filled dough products usually include layers of dough joined together at seams. The term "layers of dough" includes sheets of dough placed over each other, as well as a single sheet of dough being folded over itself to create a two or more layers.

During cooking, handling, and eating of the filled dough products, pressure is often applied on the products. Splitting of the seams and leaking of filling are serious consumer issues with filled dough products. Once the seams split, the product becomes unattractive and messy to eat. Current methods for preparing filled dough products include cutting excess dough material at the edges of the product. Mass food preparations methods, where more than one filled dough product is made at a time, often also require that individual filled dough products be separated into individual portions. Once the edges of the filled dough product are cut, the seams of the product are then crimped to create a seal between the layers of dough. During crimping, the edges of the layers of dough are pinched, stamped or pressed together.

Sometimes, a ridged, ribbed or wave pattern also is made on the seam to attempt to create a better seal and to increase the adhesion between the dough layers. As with any mass production process, every additional step in an assembly line increases the complexity and cost of preparing the product. There still remains a need for a method and tool for better sealing the edges of a filled dough product. It would be desirable that such method or tool did not add additional steps to the preparation process.

Accordingly, the present invention is directed to a method and tool for simultaneously cutting, crimping and docking the edges of a filled dough product. Docking is a process for providing strengthening bonds between two or more layers of dough. During docking, pins perforate a plurality of holes through at least an upper dough layer and at least penetrate a lower layer of dough. Used together with crimping, docking increases the strength of the seams, therefore, helping to prevent splits and leaks. The ability to accomplish simultaneously the tasks of cutting, crimping and docking, reduces the complexity and cost of product preparation. SUMMARY OF THE INVENTION

The present invention relates to tools and methods for simultaneously cutting and docking, crimping and docking, or cutting, crimping and docking a multi-layered seam of a dough product. A first embodiment of the invention is directed to a wheel comprising a round stainless steel disc having an axial opening, an outer face, an inner face and a circumferential edge. This wheel embodiment further includes a cutting blade, a crimping surface and a plurality of docking pins. The cutting blade extends radially away from an outer portion of the circumferential edge of the disc. The crimping surface is located on a central portion of the circumferential edge and, at the point of contact with dough layer, is generally parallel to the layers of the seam of the dough product. The docking pins extend radially away from the crimping surface. The wheel also includes a beveled smoothing skirt on an inner portion of the circumferential edge.

A second embodiment of the invention is directed to a die for cutting, crimping and docking the seams of a dough product. The die includes a cutting blade; a step crimping edge adjacent to the cutting blade; and a plurality of pins extending away from the surface of the step crimping edge.

To form a filled dough product in accordance with the present invention, a first layer of dough is placed on a preparation surface, followed by a second layer of dough placed over the first layer of dough. Selected portions of the layers of dough are pressed against the preparation surface using a cutting, crimping and docking tool in accordance with the present invention. The cutting blade of the tool cuts through an outer portion of the first and second layers of dough, defining the edge of the filled dough product. The crimping edge simultaneously crimps together an inner portion of the first and second layers of dough, while the pins perforate a plurality of holes between the first and the second layer of dough. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a plan view of a cutting, crimping and docking tool in accordance with the present invention. Figure 2 is a side elevation view of the tool illustrated in Fig. 1. Figure 3 is an enlarged isometric view of a portion of a cross-sectional cut of the tool illustrated in Fig. 1 across a portion of line 3-3. Figure 4 is an enlarged elevation view of a cross-sectional cut of the tool illustrated in Fig. 1 , during the process of cutting, crimping, and docking the seams of a filled dough product. Figure 5 is a top plan view of a cutting, crimping and docking die in accordance with the present invention.

Figure 6 is a top plan view of a second embodiment of a cutting, crimping and docking die in accordance with the present invention. Figure 7 is an elevation view of a cross-sectional cut of a portion of a normal edge of a segment of the tool illustrated in Fig. 5. DETAILED DESCRIPTION OF THE INVENTION

Figure 1 illustrates a cutting, crimping, docking wheel 10 in accordance with the present invention. The wheel 10 is a generally flat food-grade stainless steel disk having a round axial perforation 12. The wheel 10 has an outer face 22, an inner face 24, and a circumferential edge 26. On an outer portion of this edge 26, the wheel 10 has a peripheral radially protruding cutting blade 14, better seen in Figs. 2 and 3. The cutting blade 14 is shaped as a radially raised skirt angling inwardly to a sharp edge or end. In alternative embodiments, the cutting blade may be shaped as a two-sided skirt with both sides angling together to form a sharp edge. Another embodiment includes a thin "razor" type straight blade extending radially away from the wheel 10. In the embodiment shown, on a middle portion of the edge 26 adjacent to the cutting blade 14, there is a generally smooth peripheral crimping surface 16. The crimping surface 16 is a step edge having a smaller radius than the cutting blade 14 to allow space for the layers of dough to be crimped. When in use, the surfaces 22 and 24 of the wheel 10 are placed to be generally perpendicular to the layers of dough. Accordingly, the crimping surface 16 is generally perpendicular to the inner and outer faces 22 and 24 of the wheel 10. In the exemplary embodiment illustrated in Figs. 1- 4, the crimping surface 16 is generally smooth and has a width of 5 mm. The cutting blade portion of the wheel has a diameter of 4 inches (-10.2 cm.) and the round axial perforation may have, for example, a diameter of 0.5" (~1.27 cm.). The cutting blade 14 has a width of 2 mm. and is radially raised 2 mm. from the crimping surface 16. A plurality of docking pins 18 extend radially away from the crimping surface 16. To a certain extent, the dimensions and/or spacing of the pins depend on the type of dough and thickness of the layers to be crimped. The height of the pins 18 and of the cutting blade 14 in relation to the crimping surface 16 can vary depending on the thickness or number of the dough layers and on the desired final crimp size. The diameter of the docking pins 18 can be selected in part according to the desired appearance of the product and to the type of dough and cooking method used. The distance between the pins 18 and the cutting blade 14 generally can be increased or decreased depending on the desired width of the seam. The pins can be sized and arranged in different configurations depending on factors such as the desired width of the seam, the number of ligaments between the dough layers, the thickness and number of the dough layers, and the consistency of the dough.

In the present embodiment, the docking pins 18 extend generally radially away from the peripheral edge a distance, in relation to the crimping surface 16, less than the combined thickness of the layers of dough. For the present exemplary embodiment, the pins 18 in wheel 10 are aligned in a single row at regular intervals of 5 mm. around the circumference of peripheral crimping surface 16. The pins 18 have, for example, a diameter of 2 mm. and protrude a height of 2 mm. from the crimping surface 16. Other exemplary pin measurements for this embodiment are pin spacing between 5 mm. to 15 mm., pin height between 1 to 5 mm., and pin diameter between 1 to 10 mm.

The crimping ability of the wheel can be adjusted for different thicknesses of dough layers by varying the radial dimensions of the cutting blade and the docking pins. In other embodiments, the crimping surface includes ribs or waves to create a patterned seam. In yet other embodiments, the blade and the pins extend radially away from the edge a distance larger than the thickness of both dough layers, such that the edge does not contact the dough and the wheel lacks a crimping function. Another alternative configuration includes a wheel having a crimping edge and docking pins, without a cutting blade. Such an embodiment can be rolled over desired locations for seams and ligaments on a dough product.

On an inner portion of the edge 26 of the present embodiment, adjacent to the other side of the crimping surface 16 (the side toward surface 24), the wheel 10 includes a peripheral beveled smoothing skirt 20. The smoothing skirt 20 curves radially inward from the crimping surface 16. In the embodiment illustrated, the skirt 20 may, for example, have a width of 2 mm. In other embodiments, depending on the type and appearance of product to be produced, the smoothing skirt may have a different shape or dimensions or may be absent altogether.

Figure 4 illustrates the use of wheel 10. During production of a filled dough product, a long sheet of uncooked dough 30 is placed on a preparation surface 50, such as a conveyor belt. A dispensing machine deposits predetermined amounts of filling 60 at regular intervals on the layer of dough 30. The layer of dough 30 is then either folded over the filing 60 or a second sheet of dough is placed over the initial sheet to provide a second layer of dough 40. The locations on the dough where the seams will be placed are moistened by applying a fine mist of water using a sprayer. Alternatively, the present invention can be used without the water misting step and can be used with doughs of varying moisture levels. Although, under traditional methods, dry doughs do not crimp seal well, docking can be used to create sealed seams even with dry doughs.

The wheel 10, which is threaded on a rod along axial opening 12, is rolled over the locations for the seams. More than one wheel can be used simultaneously to cut and seal opposite edges of a same filled dough product or to mass produce more than one filled dough product. A plurality of wheels can be threaded on the same axle or rod at regular intervals (such as the width or length of a desired product) to produce a plurality of generally parallel seams.

As seen in Fig. 4, the wheel 10 simultaneously cuts both layers of dough 30 and 40 against the preparation surface 50 using cutting blade 14, and crimps the edges of the layers of dough 30 and 40 using crimping surface 16. The crimping surface 16 compresses or pinches the two layers 30 and 40 together in order to create a seal and to increase interlayer adhesion. The wheel 10 can be configured to have a weight sufficient by itself to perform the cutting, crimping and docking, or a normal force can be applied to the wheel 10 for this purpose. The docking pins 18 simultaneously create a plurality of small holes along the edge of the seam. The docking pins 18 perforate through at least the upper layer of dough 40, and at least penetrate the lower layer of dough 30. Preferably, the docking pins 18 penetrate all the way through both layers of dough 30 and 40. When the filled dough product is cooked, these holes will form rivet-like bonds joining the first layer 30 with the second layer 40.

Figure 5 illustrates a second embodiment of a cutting, crimping, docking die 100, in accordance with the present invention. The die 100 is similar in operation to a cookie cutter, and can be pressed down on layers of dough to cut them into a desired shape. The specific embodiment 100 shown in Figure 5 includes an outer peripheral rim portion or segment 101 shaped generally as a rectangle and a plurality of intermediate peφendicular wall portions or segments 102 subdividing the die into a series of generally rectangular stamps. The dimensions of each rectangular stamp match the desired dimensions of the desired dough products. The embodiment allows for the stamping of a row of rectangular products simultaneously. The number of stamps can change depending on the width of the production line. Those skilled in the art readily will appreciate that a variety of different die designs matching the shapes of different products or the desired location of different seam patterns can be achieved in accordance with the present invention. Figure 6 illustrates a second embodiment of a die 110 in accordance with the present invention having a second die design, The die 110 is configured as a series of joined "H" shaped segments, that is, as a long longitudinal bar segment 111 having opposite laterally extending leg segments 112.

The die 110 is designed to simultaneously cut and seal one end and two halves of two sides of pairs of rectangular filled dough products on an assembly line preparation surface. The die 110 illustrated in Figure 6 has several pairs of leg segments 112. The number and size of the leg segments 112 can vary depending on number of dough products to be stamped at a time (which, in turn, depends on the size of the dough product and the size of the sheets of dough to be stamped). Other alternative die shapes include round or oval patterns (for example, for filled dough products, such as ravioli or wontons), triangles, squares, other polygons or any other desired product shape.

The rim segment 101 and wall segments 102 of the die 100 and the bar segment 111 and the leg segments 112 of die 110 include generally flat food-grade stainless-steel plates aligned generally peφendicular to preparation surface 150 (illustrated in Figure 7). The segments 101, 102, 111 and 112 include a normal edge facing the preparation surface. The normal edge of the segments 101, 102, 111 and 112 resemble the circumferential edge of wheel 10 of Figs. 1-4.

Figure 7 illustrates a detail view of the normal edge of one of the segments 101. 102, 111 and 112. Two mirror-image cutting, crimping and docking edges 120 and 130 are placed back to back. Each cutting, crimping and docking edge 120 and 130 has a cutting blade 114. a step edge including a recessed smooth crimping surface 116, a plurality of docking pins 118 and a beveled smoothing skirt 120. The cutting blades 114 are angled towards each other so as to reduce suφlus wasted dough to a minimum. Alternate embodiments can include different blade designs. Those skilled in the art readily will appreciate that the crimping surface 116 can be modified to include ribs, grooves or other types of crimping patterns as desired.

Both the cutting blade 114 and the pins 118 protrude vertically away from a normal edge of the die 110. In an alternative embodiment, the cutting blade is absent, and the resulting tool is used for simultaneously docking and crimping to create seam patterns joining dough layers. In other embodiments, the cutting blade and the docking pins extend from the normal edge surface a distance greater than the thickness of the layers of dough product, such that the normal edge surface does not act as a crimping surface. In yet other embodiments, certain crimping portions of the normal edge surface are recessed from the cutting blade edge a distance less than the thickness of the layers of dough, while other portions are recessed a distance equal to or greater than the thickness of the layers of dough.

When using the dies 100 and 110, a sheet of dough is placed on the preparation surface 150. Portions of filling 160 are deposited at regular intervals on a grid pattern on the sheet of dough. The sheet of dough is folded over or a second sheet is applied over the first sheet to create two layers of dough 140 and 142. The die is then pressed against the layers of dough 140 and 142 and against the preparation surface 150 to simultaneously cut, crimp and dock the seams of the dough products. The method of using the dies also can include applying a fine mist of water to the seam sections of the dough layers to further increase interlayer adhesion, although the dies can operate on dry doughs.

Although a preferred embodiment of this invention has been described hereinabove in some detail, it should be appreciated that a variety of embodiments will be readily available to persons utilizing the invention for a specific end use. The description of the apparatus and method of this invention is not intended to be limiting on this invention, but it is merely illustrative of the preferred embodiment of this invention. Other apparatus and methods that incoφorate modifications or changes to that which has been described herein are equally included within this application. Additional objects, features, and advantages of the present invention will become apparent by referring to the above description of the invention in connection with the accompanying drawings.

Claims

CLAIMS:

1. A wheel for simultaneously cutting and docking edges of a dough product, the wheel comprising:

5 a peripheral radially protruding cutting blade; a peripheral edge surface; and a plurality of docking pins radially extending from the peripheral edge surface.

2. The wheel of claim 1 , wherein the docking pins extend from the peripheral edge surface [0 a distance less than the thickness of the edges of the dough product and the peripheral edge surface acts as a crimping surface on the edges of the dough product.

3. The wheel of claim 1 , further including a peripheral smoothing skirt adjacent to the peripheral edge surface. 5

4. The wheel of claim 1, wherein the wheel is stainless steel.

5. The wheel of claim 1, wherein the cutting blade extends from an outer portion of a circumferential edge of the wheel and the edge surface is generally on a middle portion of the 0 circumferential edge.

6. The wheel of claim 1, wherein the wheel is configured to have a weight sufficient for the cutting blade to cut through a predetermined number of layers of dough when the wheel is rolled over the layers of dough. 5

7. The wheel of claim 1 , wherein the cutting blade has a cutting edge adjacent to the edge surface.

8. The wheel of claim 1 , wherein the pins are aligned in a single row and are spaced at 0 regular intervals around the circumference of the wheel.

9. A wheel for simultaneously crimping and docking seams joining layers of dough against a preparation surface, the wheel comprising: a peripheral edge having a crimping surface; and a plurality of pins extending generally radially away from the peripheral edge, the pins protruding a distance in relation to the crimping surface less than the combined thickness of the layers of dough.

10. The wheel of claim 9, further including a peripheral smoothing skirt adjacent to the peripheral edge surface.

1 1. The wheel of claim 9, wherein the wheel is stainless steel.

12. The wheel of claim 9, wherein the pins protrude from the crimping surface.

13. The wheel of claim 9, wherein the wheel is configured to have a weight sufficient for the crimping surface to press together a predetermined number of layers of dough and for the pins to penetrate at least a portion of the layer of dough closest to the preparation surface.

14. The wheel of claim 9, wherein the pins are a same size, are aligned in a single row and are spaced at regular intervals.

15. A wheel for simultaneously cutting, crimping and docking multi-layered seams of a dough product, the wheel comprising: a) a round stainless steel disc having an outer face, an inner face and a circumferential edge; b) a cutting blade radially extending away from an outer portion of the circumferential edge of the disc; c) a generally smooth crimping surface generally parallel to the layers of the seam of the dough product, the crimping surface located on a central portion of the circumferential edge; and d) a plurality of docking pins radially extending away from the crimping surface.

16. The wheel of claim 15, further comprising a beveled smoothing skirt on an inner portion of the circumferential edge.

17. A tool for cutting and docking a predetermined number of layers of dough, the tool comprising: a) a longitudinally oriented cutting edge; b) a generally laterally oriented edge surface longitudinally recessed from the cutting edge; c) a plurality of pins protruding generally longitudinally away from the edge surface.

18. The tool of claim 17, wherein at least portions of the edge surface are recessed a distance less than the thickness of the layers of dough and the portions of the edge surface crimp the layers of dough together.

19. The tool of claim 17, further comprising a smoothing portion contiguous to the edge surface, the smoothing portion having a longitudinally receding angled surface.

20. The tool of claim 17, wherein the edge surface is generally smooth.

21. A die for cutting and docking the seams of a dough product, the die comprising: a) a cutting blade; b) a step edge adjacent to the cutting blade; c) a plurality of pins extending away from the surface of the step edge.

22. The die of claim 21 , wherein the step edge is a crimping edge that presses together the seams of the dough product.

23. The die of claim 21 , the step edge having a generally flat surface.

24. The die of claim 21 , further comprising a curved smoothing surface adjacent to the step edge.

25. The die of claim 21, wherein the pins are aligned in a single row generally parallel to the cutting blade.

26. The die of claim 21 , further comprising a first segment generally aligned with a longitudinal axis, and a plurality of secondary segments coupled to the first segment extending generally parallel to a lateral axis, wherein the cutting blade and the step edge are located on a normal edge of one of the segments.

27. The die of claim 26, further comprising a cutting blade, a crimping surface, and a plurality of docking pins disposed on a normal edge of each segment.

28. The die of claim 26, wherein each segment is a generally planar plate of stainless steel.

29. The die of claim 27, further comprising a beveled smoothing skirt adjacent to each crimping surface.

30. The die of claim 26, wherein the secondary segments are arranged in opposite extending pairs disposed at regular intervals along the first segment.

31. A method for forming filled dough products including a plurality of layers of dough joined at seams, the method comprising the steps of: a) providing a first layer of dough; b) placing a second layer of dough over the first layer of dough; c) rolling a wheel over desired locations for the seams, the wheel comprising a peripheral radially protruding cutting blade, a peripheral edge surface, and a plurality of docking pins radially extending from the edge surface; wherein the cutting blade cuts through an outer portion of the first and second layers of dough and the docking pins perforate a plurality of holes through at least a portion of the first and the second layer of dough.

32. The method of claim 31 , wherein the peripheral edge surface simultaneously crimps together a portion of the first and second layers of dough.

33. The method of claim 31 , further comprising the step of moistening the desired location for the seams.

34. The method of claim 33, wherein the step of moistening includes spraying the desired locations for the seams with a water mist.

35. The method of claim 31 , further comprising the step of simultaneously rolling at least one more wheel over other desired locations for seams on the dough layers, the wheels comprising a peripheral radially protruding cutting blade, a peripheral edge surface, and a plurality of docking pins radially extending from the edge surface; wherein the cutting blade cuts through an outer portion of the first and second layers of dough and the docking pins perforate a plurality of holes through at least a portion of the first and the second layer of dough.

36. A method for forming filled dough products including a plurality of layers of dough joined at seams, the method comprising the steps of: a) providing a first layer of dough placed on a preparation surface; b) placing a second layer of dough over the first layer of dough; c) creating the seams by pressing selected portions of the layers of dough against the preparation surface using a die, the die comprising a cutting blade, a step edge adjacent to the cutting blade and a plurality of pins extending away from the surface of the step edge; wherein the cutting blade cuts through an outer portion of the first and second layers of dough and the pins perforate a plurality of holes through the second layer of dough and through at least a portion of the first layer of dough.

37. The method of claim 36, wherein the step edge surface crimps together a portion of the first and second layers of dough.

38. The method of claim 36, further comprising the step of moistening the selected portions of the layers of dough.

39. The method of claim 38, wherein the step of moistening the selected portions includes spraying the selected portions with a water mist.

40. A die for crimping and docking seams joining layers of dough, the die comprising: a) an edge having a crimping surface for pressing together the layers of dough; b) a plurality of docking pins extending away from the surface of the edge, the pins protruding in relation to the crimping surface a distance less than the thickness of the combined layers of dough.

41. The die of claim 40, further comprising a curved smoothing surface adjacent to an outside portion of the edge.

42. The die of claim 40, wherein the pins protrude from the crimping surface.

43. The die of claim 40, wherein the pins are aligned in a single row generally parallel to the cutting blade.