LAYERED FOOD ITEMS AND METHODS OF FABRICATING

LAYERED FOOD ITEMS AND METHODS OF FABRICATING

DESCRIPTION Related Applications

This Application claims the benefit of U.S. Provisional Patent Application

Serial Number 60/128,856, filed April 12, 1999.

Technical Field The present invention generally relates to food items and methods of fabricating, and in particular to the packaging of a food material strip in a manner appealing to consumers.

Background of the Invention

The merchandising of snack-type food products is a highly competitive business. In addition to the particular type of food material within these products, the novelty and play value are also important factors to consumers when deciding whether to purchase the product.

For example, a fruit-based snack product such as FRUIT ROLL-UPS has found wide market acceptance. This product comprises a dehydrated fruit-based strip of material that must be unrolled and pealed from the packaging. Although dehydrated fruit-based snacks are not new, the process of unrolling and pealing a strip of candy from its packaging is appealing to children and some adults.

Summary of the Invention

The present invention is a food item and a method of fabricating wherein the food item is packaged in a manner promoting marketability. The food item includes a food material strip or belt having a predetermined length and two side surfaces. In addition, a support surface adjoins at least a portion of the two side surfaces of the fruit- based strip. In an embodiment, the food item includes two material support strips, each strip having a predetermined length and width. The two support strips are fanfolded into multiple layers wherein all layers have generally the same length. Furthermore, a food strip is sandwiched between the two support strips. The food strip has a predetermined length and width. Preferably, the length of the food strip is generally equal to the length of the support material strips. Also, the width of the food strip is generally equal to, or less than, the width of the support strips. Wrapped around the longitudinal axis of the food item is a band of paper or the like.

The food item can be fabricated by depositing a strip of food onto a strip of support material. Another strip of support material is pressed onto the strip of food to form a multilayered strip wherein the food is sandwiched between the two strips of support material. The multilayered strip is cut to a predetermined length and received by a guide assembly for fanfolding the strip while depositing it into a pocket.

In another embodiment, the food item includes a fruit-based food strip having an outer surface and a length defined by a leading end and a trailing end. The strip is rolled around its leading end into a roll having multiple rotations to define two or more layers lying in contact and thus supporting each other. Adhered to the outer surface of the food strip is a granular edible coating material. Furthermore, a band is wrapped around the outer annular surface of the roll. In yet another embodiment, the food item includes a plurality of coplanar material support strips wherein each strip has a length, a width, and two side surfaces. The length of each strip is defined by a leading cut end and a trailing cut end. The width of each strip is defined by two parallel edges. Adhered to at least one side surface of each support strip is a coplanar food strip having a predetermined length and width. The length of the food strips are generally equal to the length of the support material strips.

The width of the food strips are generally equal to, or less than, the width of the support strips. Brief Description of the Drawings

In the accompanying drawings forming part of the specification, and in which like numerals are employed to designate like parts throughout the same,

FIGURE 1 is a perspective view of a food item in accordance with the present invention that has been removed from a bag and includes a strip of food material sandwiched between two fanfolded layers of support material;

FIGURE 2 is a side view of the food item of FIGURE 1;

FIGURE 3 is a cross sectional view of the food item of FIGURE 1 taken along plane 3-3; FIGURE 4 is a perspective view of another food item in accordance with the present invention that has been removed from a bag and includes two coplanar strips of food material sandwiched between two fanfolded transparent layers of support material;

FIGURE 5 is a cross sectional view of the food item of FIGURE 4 taken along plane 5-5; FIGURE 6 is a perspective view of yet another food item in accordance with the present invention that has been removed from a bag and includes a plurality of food material strips interstitially placed between a plurality of spaced coplanar strips of support material;

FIGURE 7 is a cross sectional view of the food item of FIGURE 6 taken along plane 6-6;

FIGURE 8 is a perspective view of still yet another embodiment of a food item in accordance with the present invention that has been removed from a bag and includes a coiled strip of food material coated with sugar granules and wrapped with a labeling band; FIGURE 9 is a side view of the food item of FIGURE 8;

FIGURE 10 is a top view of the food item of FIGURE 8; FIGURE 1 1 is a schematic view of a device in accordance with the present invention for fabricating the food item of FIGURE 1 and having a plurality of folding stations; and

FIGURE 12 is an elevation view of one of the folding stations of FIGURE 1 1. Detailed Description

While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail a preferred embodiment 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.

Referring to FIGURES 1-3, a food item 10 is depicted comprising a strip of food material 12 sandwiched between two strips of support material 14, 16. The food strip 12 consists of candy or a like food substance such as a sweetened fruit-based material typically referred to as a fruit leather derived from fruit purees. The food strip has two planar side surfaces 18,20, a leading end 22, an opposite trailing end 24, and two parallel edges 26,28 extending longitudinally. The length of the food strip 12 extends from the strip's leading end 22 to its trailing end 24. The width of the food strip 12 extends between the strip's parallel edges 26 and 28.

The strips of support material 14, 16 sandwiching the food strip 12 can be formed of any suitable material such as silicon parchment paper, a polyurethane film, or a polyethylene film for easily removal of the candy from the support strips. Each support strip 14, 16 has a predetermined length and width. Preferably, the length of the support strips 14, 16 are equal to the length of the food strip 12. Moreover, the width of the support strips 14, 16 are equal to, or greater than, the width of the food strip 12. The strips of support material 14, 16, with the food strip 12 sandwiched therebetween, are fanfolded to form several generally coplanar overlapping layers 30 of equal length. Each layer includes two generally coterminous portions of support material 14, 16 adjoining opposite planar sides 32,34 of a portion of the food strip 12. Preferably, the leading end 22 of the strip 12 defines the terminal end of the bottom layer and the trailing end of the strip defines the terminal end of the top layer

Wrapped around the folded food item 10 about its longitudinal axis is a label 36 consisting of a continuous band of paper or the like for preventing the food item from unfolding Preferably, the band 36 encircles the longitudinal axis of the folded food item

10 about its median, but in another embodiment the band can encircle the lateral axis of the food item In addition, the folded food item 10, wrapped with the band 36, can be enclosed within a sealed plastic bag 38 or the like for preserving the freshness of the food material strip 12 Turning to FIGURE 11, a schematic view is provided of a device in accordance with the present invention for fabricating the food item of FIGURE 1 The device 50 includes an extrusion head 52 for forming a plurality of spaced, parallel, narrow strips of food 12 having a thinness requiring external support The strips are extruded upon a continuous web or sheet of support mateπal 14 Accordingly, the extrusion head 52 receives a food material that is heated to an amorphous state allowing for even extrusion of the strips of food 12 onto the moving sheet of support material 14

As stated previously, the support material 14 can be formed of any suitable material having the necessary strength to support the food 12 without tearing and allowing for fanfolding the food between layers of the support material into a compact food piece that can be easily separated from the support mateπal for consumption

Preferably, the support material 14 consists of polyurethane and is supplied in a roll The support material 14 is pulled from the extrusion head 52 and through a cooling tunnel 54 by a conveyer 56

After the food strips 12 are placed on the sheet of support material 14, and before the cooling tunnel 54, the support material is cut into strips by a cutting section

58 The cuts are made in the spacing between the strips of food 12 located on the sheet of support material 14 to form longitudinally extending continuous, multiple strips of support matenal with food placed thereon It should be noted that the cutting preferably occurs only through the support material 14 and cutting food longitudinally does not occur. In the most preferred form, the cutting is performed by a plurality of spaced, stationary water knives arranged parallel to each other and transverse to the direction of travel of the sheet of support material 14 moving past the knives. Next, support material strips having food placed thereon are passed through the cooling tunnel 54 by conveyor 56. The temperature of the food 12 is lowered as it passes through the cooling tunnel for converting the food from an amorphous state to a pliable solid.

The strips of support material 14 and food 12 are then passed onto an incline conveyor 60 for transporting the strips onto an elevated conveyor system 62 consisting of a plurality conveyors 64 separated from each other by a plurality of divides 66.

Mounted below the elevated conveyor system 62 are a plurality of folding stations 68 for fanfolding the strips as explained in detail further herein.

Mounted above the elevated conveyor system 62 are a plurality of reels 70. Each reel 70 corresponds to one of the plurality of support material strips 14 having food material 12 mounted thereon. Coiled onto each reel 70 is a length of support material 16 having substantially the same width and made of the same material as the support strip

14 carrying the food 12.

The support material 16 from each reel 70 is received by a positive drive roller pair 72 mounted over the food 12 carried by one of the lower support strips 14.

Each drive roller pair 72 unrolls the support material 16 from reel 68 and feeds the support material to a pressure roller 74 mounted over the food 12 and adjacent to the elevated conveyor 64. The pressure roller 74 presses the support material 16 onto the food 12 resulting in a multilayered strip 76 wherein the food 12 is sandwiched between the two support material strips 14,16.

The multilayered strip 76 is transferred from the elevated conveyor 64 onto an inclined chute 78. The leading end 80 of the strip 76 is received between a pair of guides or drive assemblies 82,83 and the strip is cut by a knife 84 to define a trailing or cut end 86 of the strip

Turning to FIGURE 12, the outer perimeter of drive assemblies 82 and 83 are surrounded by endless belts 88 and 89, respectively, for advancing the multilayered strip through a pivoting guide member 93 and into a pocket 94 With respect to FIGURE 12, belt 88 is driven in a clockwise direction by shaft 91 (FIGURE 1 1), and belt 89 is driven in a counterclockwise direction by shaft 90 (FIGURE 11) for advancing the multilayered strip 76 between the belts

The multilayered strip 76 is received between the belts 88,89 of the drive assemblies 82,83 and advanced therefrom into a passage 95 through the guide member

93 Preferably, the belts 88,89 are in pressing engagement with the multilayered strip 76 to prevent slippage of the strip as it is being advanced by the belts In an embodiment, a fixed planar support surface 97 abuts against belt 88, opposite the multilayered strip, and a spring loaded compression plate 99 abuts against belt 89, also opposite the multilayered strip, for maintaining the belts in pressing engagement with the strip

The guide member 93 which receives the strip 76 from the drive assemblies 82,83 preferably includes a pivot end 73 and a free end 75 As shown in FIGURE 12, the end of a shaft 77 is attached proximate to the pivot end 73 of the guide member 93 The shaft 77 is operably connected to a drive means (not shown) for rotation of the shaft Preferably, the rotational direction of the shaft 77 is alternated to result in reciprocating movement of the free end 75 of the guide 93 about a semicircular path 92 Accordingly, the multilayered strip 76 is moved back and forth as the strip passes from the free end 75 of the guide 93

An indicated previously, the leading end 80 of the multilayered strip 76 is deposited into a pocket 94 after passing through the guide 93 Further, as the strip 76 is continued to be moved back and forth by the guide 93, fanfolding of the strip occurs within the pocket 94 as the strip is being deposited into the pocket Once the cut end 86 of the strip 76 is deposited into the pocket 94, a conveyor 96 is operated to empty the contents of the pocket Further, the fanfolded strip can be further processed, if desired, such as surrounding the folded strip with a band 36 (FIGURE 1) and then packaged into a bag by conventional means In an embodiment, the pocket 94 is defined by a portion of the surface o conveyor 96 and two end walls 79 proximate to the conveyor surface Each end wall 79 is operably connected to a respective pneumatic actuator 81 for extracted the walls away from the surface of the conveyor 96, thus allowing the fanfolded stπp to be removed from the pocket 94 by movement of the conveyor belt Although one food strip is shown in the embodiment of FIGURES 1-3, other embodiments in accordance with the present invention include, but are not limited to, two or more food strips sandwiched between two strips of support material For example, as shown in FIGURES 4 and 5, the food item can include two coplanar strips 1 12a, 1 12b of food material that adjoin each other along one edge of both strips Preferably, the food strips 1 12a, 1 12b have the same length extending from each strip's leading end to its trailing end Furthermore, it is desired that the food strips 1 12a, 1 12b, have the same width extending between each strip's parallel side edges

The food strips 1 12a, 1 12b can have different colors and flavors Fo example, one strip can be red m color and have a strawberry flavor while the other stri can be orange in color and have an orange flavor Moreover, as shown in FIGURES and 5, the strips of support material 1 14, 1 16 sandwiching the food stπps 1 12a, 1 12b ca be formed of a visually transparent plastic or the like

Turning to FIGURES 6 and 7, another embodiment of a food item i accordance with the present invention is depicted The food item 210 includes a pluralit of food material strips 212 interstitially placed between a plurality of spaced coplana strips of support mateπal 214

The food stπps 212 have substantially the same size and consist of fruit-based material wherein each stπp has two planar side surfaces 218,220, a leadin end 222, an opposite trailing end, and two parallel edges 226,228 extending longitudinally Preferably, the food stπps 212 have the same color and flavor However, in an alternative embodiment, the food stπps 212 can have different colors and flavors Moreover, the food strips 212 can be embossed with an artful or fanciful design The strips of support material 214 are generally equally sized with each support strip having a predetermined length and width Preferably, the length of the support strips 214 are equal to the length of the food strips 212 Moreover, the width of the support strips 214 are equal to, or greater than, the width of the food strips 212

The strips of support material 214, with the food stπps 212 interstitially placed therebetween, form several generally coplanar layers 230 of equal length Each layer 230 includes one stπp of food material 212 adjoining at least one stπp of support material 214 Although only one food strip 212 is shown in FIGURES 6-7 as being disposed between every two juxtaposed strips of support material 214, it is to be understood that the present invention includes, but should not be limited to, more than one food strip sandwiched between two layers of support mateπal 214

Turning to FIGURES 8-9, another embodiment of a food item in accordance with the present invention is depicted having a coiled strip of food material coated with sugar granules and wrapped with a labeling band The food strip 312 consists of a fruit leather and has two planar side surfaces 318,320, a leading end 322, an opposite trailing end 324, and two parallel longitudinal edges 326,328

The strip of food material 312 is coated on both side surfaces with sugar or the like The stπp 312 is coiled multiple times around the leading end 322 of the strip to define a plurality of loops or layers in overlapping relationship Each loop or layer has a side surface in contact with, and thus supported by, another side surface of the strip of food material 312

Wrapped around the outer annular surface 340 of the coiled food item 310 is a label consisting of a band 336 of paper or the like to prevent uncoiling of the food item Moreover, the coiled food item 310 can be enclosed within a sealed plastic bag 338 or the like to preserve the freshness of the food strip.

While the 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.